Dodge - Grand Caravan - Workshop Manual - 2005 - 2005

Factory Workshop Manual Make Dodge Model Grand Caravan Engine and year V6-3.3L VIN R (2005) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8 Accessory Delay Relay: Description and Operation ACCESSORY RELAY The accessory relay is an electromechanical device that switches fused battery current to the accessory powered vehicle circuits when the ignition switch is turned to the Accessory or ON positions. The delay feature will maintain power to the accessories for 45 seconds after the ignition is shut OFF or until a door is opened. This allows sufficient time to close windows and park the windshield wipers. The accessory relay is located in the Integrated Power Module (IPM) in the engine compartment. The accessory relay is a International Standards Organization (ISO) relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The accessory relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams Thatcham Alarm Module (united Kingdom) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 12 Alarm Module: Service and Repair PROGRAMMING THE SENTRY KEY REMOTE ENTRY MODULE NOTE: If the PCM and the SKREEM are replaced at the same time program the VIN into the PCM first. All vehicle keys will then need to be replaced and programmed to the new SKREEM. 1. Turn the ignition on (transmission in park/neutral). 2. Use the DRBIII(R) and select THEFT ALARM SKREEM then MISCELLANEOUS. 3. Select SKREEM MODULE REPLACEMENT (GASOLINE). 4. Program the vehicle four-digit PIN into the SKREEM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKREEM the SKREEM must be replaced. 6. Select UPDATE VIN (the SKREEM will learn the VIN from the PCM). 7. Press ENTER to transfer the VIN (the PCM will send the VIN to the SKREEM). 8. The DRBIII(R) will ask if you want to transfer the secret key. Select ENTER to transfer secret key from the PCM. This will ensure the current vehicle ignition keys will still operate the SKREES system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Description and Operation Antenna Control Module: Description and Operation The antenna module is an electromagnetic circuit component designed to capture and enhance RF (Radio Frequency) signals in both the AM and FM broadcast bands. The antenna module is mounted to the right rear roof rail under the headliner. The module is grounded through the mounting bracket and fastener. The module has a two wire electrical connector that connects to the integral radio antenna,located on the right rear quarter glass. There is also an electrical connector for battery voltage and a coax cable connector. The antenna module receives both AM and FM radio signals supplied by the side window integral radio antenna system and selectively amplifies them. The amplified signal is then sent through the body length coax cable to the radio input. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Description and Operation > Page 16 Antenna Module - Export Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Description and Operation > Page 17 Antenna Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Antenna Module 2. Lower headliner as necessary to access antenna module. 3. Disconnect antenna coax cable lead and electrical harness connector from antenna module. 4. Disconnect the antenna module connector from the quarter glass. 5. Remove the mounting screw and the antenna module. INSTALLATION 1. Install the antenna module and the mounting fastener. 2. Connect the antenna connector to the quarter glass. 3. Connect the antenna lead and electrical connector to the antenna module. 4. Raise and install headliner. 5. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Ignition Shut Down Relay (For Antitheft) > Component Information > Description and Operation Ignition Shut Down Relay (For Antitheft): Description and Operation AUTO SHUT DOWN RELAY The relay is located in the Power Distribution Center (PDC). For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary The engine switched battery (NGC vehicles) informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is also used to power certain drivers on NGC vehicles. When energized, the ASD relay on NGC vehicles provides power to operate the injectors, ignition coil, generator field, O2 sensor heaters (both upstream and downstream), evaporative purge solenoid, EGR solenoid (if equipped) wastegate solenoid (if equipped), and NVLD solenoid (if equipped). The ASD relay also provides a sense circuit to the PCM for diagnostic purposes. If the PCM does not receive 12 volts from this input after grounding the control side of the ASD relay, it sets a Diagnostic Trouble Code (DTC). The PCM energizes the ASD any time there is an engine speed that exceeds a predetermined value (typically about 50 rpm). The ASD relay can also be energized after the engine has been turned off to perform an O2 sensor heater test, if vehicle is equipped with OBD II diagnostics. As mentioned earlier, the PCM energizes the ASD relay during an O2 sensor heater test. On NGC vehicles it checks the O2 heater upon vehicle start. The PCM still operates internally to perform several checks, including monitoring the O2 sensor heaters. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations > Page 25 Keyless Entry Module: Connector Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations > Page 26 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations > Page 27 Steering Column Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations > Page 28 Center Instrument Panel Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations > Page 29 Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 30 Sentry Key Remote Entry Module (Skreem) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 31 Keyless Entry Module: Description and Operation The Sentry Key Remote Entry Module (SKREEM) performs the functions of the Sentry Key Immobilizer Module (SKIM), Remote Keyless Entry (RKE) Module, and the Tire Pressure Monitoring (TPM) System (previously part of the Electronic Vehicle Information Center (EVIC). The SKREEM is located in the same location as the SKIM was and is mounted the same way. It looks identical, but has added capabilities. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 32 Keyless Entry Module: Testing and Inspection For proper diagnosis and testing of the Sentry Key Remote Entry Module (SKREEM), use a DRBIII (R) and refer to the proper Body Diagnostic Procedures information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 33 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the Steering Column Opening Cover. 3. Remove the steering column upper and lower shrouds. 4. Disengage the steering column wire harness from the Sentry Key Remote Entry Module (SKREEM). 5. Remove the one screws securing the SKREEM to the steering column. 6. Rotate the SKREEM upwards and then to the side away from the steering column to slide the SKREEM antenna ring from around the ignition switch lock cylinder housing. 7. Remove the SKREEM from the vehicle. INSTALLATION 1. Slip the Sentry Key Remote Entry Module (SKREEM) antenna ring around the ignition switch lock cylinder housing. Rotate the SKREEM downwards and then towards the steering column. 2. Install the one screws securing the SKREEM to the steering column. 3. Connect the steering column wire harness to the SKREEM. 4. Install the steering column upper and lower shrouds. 5. Install the Steering Column Opening Cover. 6. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations Left Rear Body Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 37 Park Assist Module (Parktronics) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 38 Parking Assist Control Module: Description and Operation Park Assist Module Park Assist Module - Location The Park Assist Module is located on the left side of the vehicle, behind the quarter trim panel, just behind the C-pillar. It is has a molded plastic housing which housing internal circuitry and one electrical connector. There are two mounting tabs that affix the module to the left inner quarter panel with two screws. The module has a number of functions: - Supply voltage to the sensors and display. - Disconnection of the display with bus idle and over voltage Vmax. - Triggering the sensors. - Analyze echo delay times and calculate obstacle distances. - Bi-directional data communication to the display for diagnosis. - System diagnostics - diagnosis and error handling (sensors, display, module). - Data exchange over the Programmable Communication Interface (PCI) data bus. The module has a number of functions: - Supply voltage to the sensors and display. - Disconnection of the display with bus idle and over voltage Vmax. - Triggering the sensors. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 39 - Analyze echo delay times and calculate obstacle distances. - Bi-directional data communication to the display for diagnosis. - System diagnostics - diagnosis and error handling (sensors, display, module). - Data exchange over the Programmable Communication Interface (PCI) data bus. The system detection length from the rear of the vehicle is 0.3 meters to 1.5 meters. This area extends around the rear side of the vehicle. The system detection height from the ground is 0.2 meters to about 1.5 meters. The radio mutes when the system activates its audible tone. When the driver selects Reverse, the system scans for objects behind the vehicle using four sensors located in the rear bumper. Objects can be detected from up to 1.5 meters. A warning display above the rear window provides both visible and audible warnings indicating the range of the object. The system is active only when the vehicle is in reverse for vehicle speeds less than 16 Km/h (10 mph). If the vehicles Parking/Emergency Brake is applied, the system is deactivated. The display contains two sets of yellow and red Light Emitting Diode's (LED's) that the driver can see as they look over their shoulder while backing up. Each side of the vehicle has its own warning LED's. The system provides a visual warning by illuminating one or more yellow LED's as the vehicle gets closer to the object. As the vehicle continues to approaches the object, one red LED is illuminated and the system emits a series of short beeps. The tone will remain constant and both red LED's are illuminated once the vehicle is within 12 inches (30.5 cm) of the object. The system can be turned ON or OFF through the Electronic Vehicle Information Center (EVIC) when the vehicle is in PARK. If the park assist system is turned OFF, a single chime will sound and the EVIC will display the following message "REAR PARK ASSIST OFF", when the vehicle is in reverse. - Ensure that the rear bumper is free of dirt and debris to keep the system operating properly. - Jackhammers, large trucks, and other vibrations could affect the performance of the system. - Ensure that the parking brake is not applied. If "Service Park Assist System" appears in the EVIC after making sure the rear bumper is clean, proceed to diagnose the system using a scan tool and the appropriate diagnostic information. To diagnose the Park Assist Module, use a scan tool and the appropriate body diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 40 Parking Assist Control Module: Service and Repair REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Remove the left quarter trim panel. Park Assist Module Electrical Connector 4. Disconnect the Park Assist Module electrical connector. Park Assist Module Location 5. Remove the two attaching screws and separate the module from vehicle. INSTALLATION 1. Position the Park Assist Module and install the two attaching screws. Torque screws to 3.5 Nm (30 in. IDS.). 2. Connect the Park Assist Module electrical connector. 3. Install the left quarter trim panel. 4. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Locations > Page 44 Pedal Positioning Module: Diagrams Memory Seat/Mirror/Adjustable Pedals Module C1 Memory Seat/Mirror/Adjustable Pedals Module C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Locations > Page 45 Memory Seat/Mirror/Adjustable Pedals Module C3 Memory Seat/Mirror/Adjustable Pedals Module C4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Diagrams Voice Activation Module: Diagrams Hands Free Module C1 Hands Free Module C2 Hands Free Module C3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Diagrams > Page 52 Voice Activation Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel lower console. Hands Free Module 3. Remove the mounting fasteners. 4. Disconnect the electrical harness connector and remove module. INSTALLATION 1. Connect electrical harness connector and position module. 2. Install mounting fasteners. 3. Install instrument panel lower console. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations > Page 61 Keyless Entry Module: Connector Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations > Page 62 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations > Page 63 Steering Column Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations > Page 64 Center Instrument Panel Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations > Page 65 Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 66 Sentry Key Remote Entry Module (Skreem) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 67 Keyless Entry Module: Description and Operation The Sentry Key Remote Entry Module (SKREEM) performs the functions of the Sentry Key Immobilizer Module (SKIM), Remote Keyless Entry (RKE) Module, and the Tire Pressure Monitoring (TPM) System (previously part of the Electronic Vehicle Information Center (EVIC). The SKREEM is located in the same location as the SKIM was and is mounted the same way. It looks identical, but has added capabilities. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 68 Keyless Entry Module: Testing and Inspection For proper diagnosis and testing of the Sentry Key Remote Entry Module (SKREEM), use a DRBIII (R) and refer to the proper Body Diagnostic Procedures information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 69 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the Steering Column Opening Cover. 3. Remove the steering column upper and lower shrouds. 4. Disengage the steering column wire harness from the Sentry Key Remote Entry Module (SKREEM). 5. Remove the one screws securing the SKREEM to the steering column. 6. Rotate the SKREEM upwards and then to the side away from the steering column to slide the SKREEM antenna ring from around the ignition switch lock cylinder housing. 7. Remove the SKREEM from the vehicle. INSTALLATION 1. Slip the Sentry Key Remote Entry Module (SKREEM) antenna ring around the ignition switch lock cylinder housing. Rotate the SKREEM downwards and then towards the steering column. 2. Install the one screws securing the SKREEM to the steering column. 3. Connect the steering column wire harness to the SKREEM. 4. Install the steering column upper and lower shrouds. 5. Install the Steering Column Opening Cover. 6. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 73 Memory Positioning Module: Description and Operation Vehicles equipped with the memory seat/mirror option, utilize a memory module located under the drivers front seat. This module is basically wired in-line between the power seat switch and the power seat track/adjuster motors, or in-line between the power mirror switch and the power side view mirror(s) motor(s). The Memory Seat/Mirror Module (MSMM) contains a central processing unit that communicates with other modules on the Programmable Communications Interface (PCI) data bus network. The MSMM receives hard wired inputs from the driver power seat switch and the potentiometers on each of the driver side power seat track motors, or from the power mirror switch and the potentiometers on the side view mirror. The MSMM receives messages over the PCI data bus from the Body Control Module (BCM) (memory switch status), the Powertrain Control Module (PCM) (vehicle speed status). The MSMM will prevent the seat memory recall function from being initiated if the driver side seat belt is buckled, if the transmission gear selector lever is not in the Park or Neutral positions, or if the vehicle is moving. For diagnosis of the MSMM or the PCI data bus, a DRB III(R) scan tool and the proper Diagnostic Procedures Information are recommended. The MSMM cannot be repaired and, if faulty or damaged, it must be replaced. When memory system operation is requested (depressing of the memory switch), a resistor multiplexed signal is sent from the memory switch to the Body Control Module (BCM). The BCM will then send the appropriate signals out to the Memory Seat/ Mirror Module (MSMM), the MSMM then applies the voltage supply to the power seat track or side-view mirror if the proper requirements are met. The vehicle speed must equal zero and the transmission must be in park or neutral in order for the memory system to function. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 74 Memory Positioning Module: Testing and Inspection Any diagnosis of the Memory Seat/Mirror system should begin with the use of the DRB III(R) diagnostic tool. Inspect the related wiring harness connectors for broken, bent, pushed out, or corroded terminals. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 75 Memory Positioning Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side front bucket seat retaining nuts from under the vehicle. 3. Lift the drivers seat up and out of the mounting holes in the floor pan and lay the seat rearward to access the module located under the seat. 4. Disconnect the memory seat/mirror module electrical connectors. Depress the retaining tab and pull straight apart. 5. Remove the module retaining bolts and remove the module from the bracket. INSTALLATION 1. Position and install the module retaining bolts. 2. Connect the memory seat/mirror module electrical connectors. 3. Position the drivers seat in the mounting holes in the floor pan. 4. Install the driver side front bucket seat retaining nuts from under the vehicle. 5. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Locations > Page 79 Pedal Positioning Module: Diagrams Memory Seat/Mirror/Adjustable Pedals Module C1 Memory Seat/Mirror/Adjustable Pedals Module C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Locations > Page 80 Memory Seat/Mirror/Adjustable Pedals Module C3 Memory Seat/Mirror/Adjustable Pedals Module C4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Relay > Component Information > Locations Left Side Engine Compartment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Relay > Component Information > Locations > Page 84 Adjustable Pedals Relay (Except Export/Except Memory) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Mirror Relay > Component Information > Diagrams Passenger Folding Mirror Relay (Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation Power Seat Control Module: Description and Operation Vehicles equipped with heated seats utilize two heated seat modules. The heated seat modules are located under the front seats, where they are secured to the seat cushion pans. Each heated seat module has three connector receptacles that allow the modules to be connected to all of the required inputs and outputs through the seat wire harness. The heated seat modules are an electronic microprocessor controlled device designed and programmed to use inputs from the ignition switch, heated seat switch and the heated seat sensor to operate and control the heated seat elements in the front seat. The heated seat module operates on fused battery current received from the Integrated Power Module (IPM). The module is grounded at all times through the seat wire harness. Inputs to the module include a resistor multiplexed heated seat switch request circuit for the heated seat switch and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements. When a heated seat switch request signal is received by the heated seat module and the enable input is high, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is approximately 36° C (95° F), and the High heat set point is approximately 40° C (104° F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the N-FET which de-energizes the heated seat elements. The heated seat module will continue to cycle the N-FET as needed to maintain the selected temperature set point. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Page 94 Power Seat Control Module: Testing and Inspection If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. If the heated seat switch checks OK, proceed as follows. 1. Check the heated seat element. 2. Check the heated seat sensor. 3. Using a voltmeter, back probe the appropriate heated seat module connector, do not disconnect. Check for battery voltage at the appropriate pin cavities. If OK go to Step 4. If not OK, repair the open or shorted voltage supply circuit as required. 4. Using a ohmmeter, back probe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK replace the heated seat module. If Not OK, repair the open or shorted ground circuit as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Page 95 Power Seat Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the appropriate front seat from the vehicle. 3. Unsnap the module from the seat cushion pan. 4. Disconnect the module wire harness connectors. INSTALLATION 1. Connect the module wire harness connectors. 2. Snap the module on the seat cushion pan. 3. Install the appropriate front seat in the vehicle. 4. Connect and isolate the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Sliding Door Module > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Sliding Door Module > Component Information > Locations > Component Locations > Page 100 Power Sliding Door Module: Connector Locations Right Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Sliding Door Module > Component Information > Locations > Component Locations > Page 101 Liftgate And Sliding Door Modules Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Sliding Door Module > Component Information > Locations > Page 102 Power Sliding Door Module: Diagrams Left Sliding Door Control Module C1 (Power Sliding Door) Left Sliding Door Control Module C2 (Power Sliding Door) Right Sliding Door Control Module C1 (power Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Sliding Door Module > Component Information > Locations > Page 103 Right Sliding Door Control Module C2 (power Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Sliding Door Module > Component Information > Locations > Page 104 Power Sliding Door Module: Description and Operation Power Side Door Components Vehicles equipped with a power sliding door system utilize a sliding door control module. The sliding door control module is located behind the sliding door trim panel in the center of the door, just above the sliding door motor. This module controls the operation of the door through the Programmable Communication Interface (PCI) data bus circuit and the Body Control Module (BCM). The sliding door control module contains software technology which enables it to detect resistance to door travel and to reverse door travel in order to avoid damage to the door or to avoid possible personal injury if the obstruction is a person. This feature functions in both the opening and closing cycles. If the power sliding door system develops any problems the control module will store and recall Diagnostic Trouble Codes (DTC). The use of a diagnostic scan tool, such as the DRB III(R) is required to read and troubleshoot these trouble codes. The sliding door control module can be reflashed if necessary. Refer to the latest Technical Service Bulletin (TSB) Information for any updates. The power door control module is a replaceable component and cannot be repaired, if found to be faulty it must be replaced. The power sliding door control module serves as the main computer for the power sliding door system. All power door functions are processed through the power sliding door control module and/or the vehicles Body Control Module (BCM). At the start of a power open command, a signal is sent to the BCM and then to the power sliding door control module via the Programmable Communication Interface (PCI) data bus circuit. This signal, generated by any of the power door command switches, tells the power sliding door control module to activate a power latch release, engage the clutch assembly and drive the door into the full open position. If an obstacle is felt during this power open cycle, the module will reverse direction and close the door. This process is also enabled during a power close cycle. This process will repeat three times, and if a fourth obstacle is detected, the door will go into full manual mode. Once the full open position is obtained, a hold open latch assembly mounted full open switch tells the power sliding door control module that the door has reached the full open position. If the power sliding door system develops any problems the power sliding door control module will store and recall Diagnostic Trouble Codes (DTC). The use of a diagnostic scan tool, such as the DRB III(R) is required to read and troubleshoot these trouble codes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Sliding Door Module > Component Information > Locations > Page 105 Power Sliding Door Module: Testing and Inspection Any diagnosis of the power sliding door system should begin with the use of the DRB III(R) diagnostic tool. Inspect the related wiring harness connectors for broken, bent, pushed out, or corroded terminals. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Sliding Door Module > Component Information > Locations > Page 106 Power Sliding Door Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the appropriate door trim panel from the vehicle. 3. Remove the weather shield. 4. Disconnect the power door control module electrical connectors. Slide the red locking tab out (away from module) and depress connector retaining tab, while pulling straight apart. Power Side Door Components 5. Remove the control module retaining screw. 6. Remove the module from the vehicle. INSTALLATION 1. Position the sliding door control module and install the retaining screw. 2. Connect the electrical connectors. Slide the locking tab into the locked position. 3. Install the weather shield. 4. Install the appropriate door trim panel on the vehicle. 5. Connect the battery negative cable. 6. Using an appropriate scan tool, check and erase any power door control module diagnostic trouble codes. 7. Verify power door system operation. Cycle the power door through one complete open and close cycle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Trunk / Liftgate Control Module: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly Power Trunk / Liftgate Control Module: Customer Interest Body - Power Liftgate Does Not Open/Close Properly NUMBER: 08-045-06 GROUP: Electrical DATE: October 17, 2006 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. WHILE THE FILES ARE CURRENTLY AVAILABLE FROM THE INTERNET FOR ALL MARKETS, FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE DRBIII(R) FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL ALSO BE AVAILABLE ON ITIL/ISIS DVD 4th QUARTER, 2006. SUBJECT: Flash: Power Liftgate May Not Open Or Close The First Time That The Power Liftgate Button Is Depressed OVERVIEW: This bulletin involves selectively erasing and reprogramming the Power Liftgate Module with new software. MODELS: 2002 - 2007 (RS/RG) Town & Country/Caravan/Voyager NOTE: This bulletin applies to vehicles equipped with a Power Liftgate (sales code JRC) built on or before October 13, 2006 (MDH 1013XX). SYMPTOM/CONDITION: The vehicle operator may describe that the Power Liftgate may not open or close the first time that the Power Liftgate button is depressed. If the button is pressed repeatedly, the liftgate will open or close properly. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII® connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE FOR DOMESTIC VEHICLES DOWNLOADING FLASH FILES FROM DealerCONNECT> Tech TOOLS: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Trunk / Liftgate Control Module: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly > Page 115 NOTE Remove any unnecessary PCMCIA cards prior to starting a DRBIII(R) flash. 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the Power Liftgate Module currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2007 Diagnostics". c. "All (Except Below)". d. "Body Interior". e. "Doors, Gates & Comfort". f. "Power Lift Module". g. "Module Display". h. Record the "Power Liftgate Module part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "Power Liftgate Module part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the '~Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to next step. NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Trunk / Liftgate Control Module: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly > Page 116 Due to the Power Liftgate Module programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Trunk / Liftgate Control Module: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly Power Trunk / Liftgate Control Module: All Technical Service Bulletins Body - Power Liftgate Does Not Open/Close Properly NUMBER: 08-045-06 GROUP: Electrical DATE: October 17, 2006 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. WHILE THE FILES ARE CURRENTLY AVAILABLE FROM THE INTERNET FOR ALL MARKETS, FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE DRBIII(R) FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL ALSO BE AVAILABLE ON ITIL/ISIS DVD 4th QUARTER, 2006. SUBJECT: Flash: Power Liftgate May Not Open Or Close The First Time That The Power Liftgate Button Is Depressed OVERVIEW: This bulletin involves selectively erasing and reprogramming the Power Liftgate Module with new software. MODELS: 2002 - 2007 (RS/RG) Town & Country/Caravan/Voyager NOTE: This bulletin applies to vehicles equipped with a Power Liftgate (sales code JRC) built on or before October 13, 2006 (MDH 1013XX). SYMPTOM/CONDITION: The vehicle operator may describe that the Power Liftgate may not open or close the first time that the Power Liftgate button is depressed. If the button is pressed repeatedly, the liftgate will open or close properly. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII® connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE FOR DOMESTIC VEHICLES DOWNLOADING FLASH FILES FROM DealerCONNECT> Tech TOOLS: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Trunk / Liftgate Control Module: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly > Page 122 NOTE Remove any unnecessary PCMCIA cards prior to starting a DRBIII(R) flash. 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the Power Liftgate Module currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2007 Diagnostics". c. "All (Except Below)". d. "Body Interior". e. "Doors, Gates & Comfort". f. "Power Lift Module". g. "Module Display". h. Record the "Power Liftgate Module part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "Power Liftgate Module part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the '~Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to next step. NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Trunk / Liftgate Control Module: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly > Page 123 Due to the Power Liftgate Module programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 124 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 125 Power Trunk / Liftgate Control Module: Description and Operation Power Liftgate Control Module Vehicles equipped with a power liftgate (PLG) utilize a PLG control module. This module is located on the vehicles left side D-pillar just below the motor assembly and contains a microprocessor, which is used to communicate to the vehicles body control module. The PLG control module receives and monitors logic inputs from all the PLG system switches except for the outside handle switch. This module also contains the software technology to detect liftgate obstructions and stop and/or reverse the door accordingly. The power liftgate control module contains the electronic circuitry and software used to control the sequence of events for the power liftgate system. This module communicates on the Programmable Communications Interface (PCI) bus circuit with the vehicles Body Control Module (BCM) to monitor many different inputs and outputs such as door lock status, transmission gear selector position and vehicle speed. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 126 Power Trunk / Liftgate Control Module: Testing and Inspection Any diagnosis of the Power Liftgate system should begin with the use of the DRB III(R) diagnostic tool. Inspect the related wiring harness connectors for broken, bent, pushed out, or corroded terminals. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 127 Power Trunk / Liftgate Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left D-pillar trim panel from the vehicle. 3. Disconnect the wire harness connections from the power liftgate motor assembly. Power Liftgate Control Module 4. Remove the screw holding the power liftgate control module to the D-pillar. 5. Remove the power liftgate control module from the vehicle. INSTALLATION 1. Install the Power Liftgate (PLG) control module on the D-pillar and install retaining screw. 2. Connect the wire harness connections to the PLG control module. Be certain to slide connector locks to the locked position. 3. Install the D-pillar trim panel on the vehicle. 4. Connect the battery negative cable. 5. Using an appropriate scan tool, check and erase any PLG control module diagnostic trouble codes. 6. Verify PLG system operation. Cycle the PLG through one complete open and close cycle, this will allow the PLG control module to relearn its cycle with the new components. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams Seat Heater Control Module: Diagrams Driver Heated Seat Module C1 Driver Heated Seat Module C2 Driver Heated Seat Module C3 Passenger Heated Seat Module (Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 131 Passenger Heated Seat Module C1 (Export) Passenger Heated Seat Module C2 (Export) Passenger Heated Seat Module C3 (Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof Module (Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 139 3.3-3.8 Liter Engine Front Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 140 Electronic Brake Control Module: Diagrams Anti-Lock Brake Module(MK25e) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 141 Controller ANTILOCK Brake (MK20E) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > System Overview Electronic Brake Control Module: Description and Operation System Overview CONTROLLER ANTILOCK BRAKE/ANTI-LOCK BRAKE MODULE The CAB/ABM is a microprocessor-based device that monitors wheel speeds and controls the antilock functions. The CAB/ABM contains two microprocessors that receive identical sensor signals and then independently process the information. The results are then compared to make sure that they agree. Otherwise, the CAB/ABM will turn off the antilock and turn on the ABS amber warning indicator. The primary functions of the CAB/ABM are to: ^ detect wheel locking tendencies ^ control fluid pressure modulation to the brakes during antilock stop ^ monitor the system for proper operation ^ manage traction control functions ^ provide communication to the DRBIII(R) while in diagnostic mode ^ store diagnostic information in non-volatile memory The CAB/ABM continuously monitors the speed of each wheel. When a wheel locking tendency is detected, the CAB/ABM will command the appropriate valve to modulate brake fluid pressure in its hydraulic unit. Brake pedal position is maintained during an antilock stop by being a closed system. The CAB/ABM continues to control pressure in individual hydraulic circuits until a wheel locking tendency is no longer present. The CAB/ABM turns on the pump motor during an antilock stop. The antilock brake system is constantly monitored by the CAB/ABM for proper operation. If the CAB/ABM detects a system malfunction, it can disable the antilock system and turn on the ABS warning indicator. If the antilock function is disabled, the system will revert to standard base brake system operation. The CAB/ABM inputs include the following: ^ diagnostic communication ^ four wheel speed sensors ^ three power feeds: valve, pump, and microprocessor ^ brake lamp switch ^ traction control switch The CAB/ABM outputs include the following: ^ ABS warning indicator actuation ^ 12 volts supply to wheel speed sensors ^ valve actuation ^ diagnostic communication ^ PCI bus communication ^ traction control lamp illumination Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > System Overview > Page 144 Electronic Brake Control Module: Description and Operation Antilock Brake Module (MK25E) The Antilock Brake Module (ABM) is a microprocessor-based device which monitors the antilock brake system (ABS) during normal braking and controls it when the vehicle is in an ABS stop or when in a traction control situation. The ABM utilizes a 47-way electrical connector on the vehicle wiring harness. The power source for the ABM is through the ignition switch in the RUN or ON position. Mk25e ICU The ABM is mounted to the HCU as part of the Integrated Control Unit (ICU). The ICU is located in the engine compartment below the master cylinder on the front suspension cradle/crossmember. The primary functions of the Antilock Brake Module (ABM) are to: - Monitor the antilock brake system for proper operation. - Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - Control fluid modulation to the wheel brakes while the system is in an ABS mode. - Store diagnostic information. - Provide communication to the scan tool while in diagnostic mode. - Illuminate the amber ABS warning indicator lamp. - (With traction control only) Illuminate the TRAC ON lamp in the message center on the instrument panel when a traction control event occurs. - (with traction control only) Illuminate the TRAC OFF lamp when the amber ABS warning indicator lamp illuminates. The ABM constantly monitors the antilock brake system for proper operation. If the ABM detects a fault, it will turn on the amber ABS warning indicator lamp and disable the antilock braking system. The normal base braking system will remain operational. NOTE: If the vehicle is equipped with traction control, the TRAC OFF lamp will illuminate anytime the amber ABS warning indicator lamp illuminates. The ABM continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the ABM commands the ABM command coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The ABM continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The ABM contains a self-diagnostic program that monitors the antilock brake system for system faults. When a fault is detected, the amber ABS warning indicator lamp is turned on and the fault diagnostic trouble code (DTC) is then stored in a diagnostic program memory. A latched fault will disable certain system functionality for the current ignition cycle. An unlatched fault will disable certain system functionality until the fault condition disappears. These DTC's will remain in the ABM memory even after the ignition has been turned off. The DTC's can be read and cleared from the ABM memory by a technician using a scan tool. If not cleared with a scan tool, the fault occurrence and DTC will be automatically cleared from the ABM memory after the identical fault has not been seen during the next 3,500 miles. Drive-off may be required for the amber ABS warning indicator lamp to go out on the next ignition cycle. ABM INPUTS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > System Overview > Page 145 - Wheel speed sensors (four) - Brake lamp switch - Ignition switch - System and pump voltage - Ground - Traction control switch (if equipped) - Diagnostic communication (PCI) ABM OUTPUTS - Amber ABS warning indicator lamp actuation (via BUS) - Red BRAKE warning indicator lamp actuation (via BUS) - Instrument cluster (MIC) communication (PCI) - Traction control lamps (if equipped) - Diagnostic communication (PCI, via BUS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > System Overview > Page 146 Electronic Brake Control Module: Description and Operation Controller Antilock Brake (MK20E) Integrated Control Unit (ICU) The controller antilock brake (CAB) is a microprocessor-based device which monitors the antilock brake system (ABS) during normal braking and controls it when the vehicle is in an ABS stop. The CAB is mounted to the HCU as part of the integrated control unit (ICU). The CAB uses a 24-way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the RUN or ON position. The CAB is on the PCI bus. The primary functions of the controller antilock brake (CAB) are to: - Monitor the antilock brake system for proper operation. - Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - Control fluid modulation to the wheel brakes while the system is in an ABS mode. - Store diagnostic information. - Provide communication to the DRBIII(R) scan tool while in diagnostic mode. - Illuminate the amber ABS warning indicator lamp. - (With traction control only) Illuminate the TRAC ON lamp in the message center on the instrument panel when a traction control event occurs. - (with traction control only) Illuminate the TRAC OFF lamp when the amber ABS warning indicator lamp illuminates. The CAB constantly monitors the antilock brake system for proper operation. If the CAB detects a fault, it will turn on the amber ABS warning indicator lamp and disable the antilock braking system. The normal base braking system will remain operational. NOTE: If the vehicle is equipped with traction control, the TRAC OFF lamp will illuminate anytime the amber ABS warning indicator lamp illuminates. The CAB continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the CAB commands the CAB command coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The CAB contains a self-diagnostic program that monitors the antilock brake system for system faults. When a fault is detected, the amber ABS warning indicator lamp is turned on and the fault diagnostic trouble code (DTC) is then stored in a diagnostic program memory. A latched fault will disable certain system functionality for the current ignition cycle. An unlatched fault will disable certain system functionality until the fault condition disappears. These DTC's will remain in the CAB memory even after the ignition has been turned off. The DTC's can be read and cleared from the CAB memory by a technician using the DRBIII(R) scan tool. If not cleared with a DRBIII(R) scan tool, the fault occurrence and DTC will be automatically cleared from the CAB memory after the identical fault has not been seen during the next 3,500 miles. Drive-off may be required for the amber ABS warning indicator lamp to go out on the next ignition cycle. CAB INPUTS - Wheel speed sensors (four) - Brake lamp switch - Ignition switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > System Overview > Page 147 - System and pump voltage - Ground - Traction control switch (if equipped) - Diagnostic communication (PCI) CAB OUTPUTS - Amber ABS warning indicator lamp actuation (via BUS) - Red BRAKE warning indicator lamp actuation (via BUS) - Instrument cluster (MIC) communication (PCI) - Traction control lamps (if equipped) - Diagnostic communication (PCI, via BUS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Brake Module (MK25E) Electronic Brake Control Module: Service and Repair Antilock Brake Module (MK25E) REMOVAL 1. Disconnect the negative (ground) cable from the battery and isolate it. 2. Remove the battery shield and battery. 3. Disconnect the vacuum hose connector at the tank built into the battery tray. 4. Remove the screw securing the engine coolant filler neck to the battery tray. 5. Remove the battery tray. CAUTION: Before disassembling the ICU, the ICU must be thoroughly cleaned. This must be done to prevent dirt particles and debris from entering into vital areas of the ICU. 6. Thoroughly clean all surfaces of the ICU and brake tubes. Use only a solvent such as Mopar Brake Parts Cleaner or equivalent. ABM Connector Release Tabs Wiring Harness Connector At ABM 7. Disconnect the 47-way connector from the antilock brake module (ABM) by depressing the tabs on each side of the connector cover (Fig. 2), then pulling outward and upward on the lower half of the cover until it locks into position pointing straight outward. The connector can then be pulled straight outward off the ABM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Brake Module (MK25E) > Page 150 ABM Mounting Screws - Without Traction Control 8. If not equipped with traction control, remove the three screws attaching the ABM to the HCU. ABM Mounting Screws - With Traction Control 9. If equipped with traction control, remove the four screws attaching the ABM to the HCU. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Brake Module (MK25E) > Page 151 ABM Assembly To HCU 10. Separate the ABM from the HCU. INSTALLATION 1. Clean any debris off the mating surfaces of the HCU and ABM. CAUTION: - Do not reuse internal pump connector O-ring or solenoid valve stem seals. They must be replaced to ensure proper sealing. - When installing new O-rings or solenoid valve stem seals, do not use any type of lubricant. Solenoid Valve Seal 2. Replace solenoid valve stem seals. These seals can be easily removed and installed by hand. Do not use any type of sharp instrument or damage to the components may occur. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Brake Module (MK25E) > Page 152 Internal Pump Connector O-Ring 3. Replace pump/motor connector O-ring if not new. 4. Align components and install the ABM on the HCU. 5. If not equipped with traction control, install the three screws attaching the ABM to the HCU. Tighten the mounting screws to 2 N.m (17 in. lbs.) torque. 6. If equipped with traction control, install the four screws attaching the ABM to the HCU. Tighten the mounting screws to 2 N.m (17 in. lbs.) torque. 7. With connector cover completely open, install 47-way wiring connector into socket of the ABM and close cover, locking connector in place. 8. Install the battery tray. 9. Install the screw securing the coolant filler neck to the battery tray. 10. Reconnect the vacuum hose connector at the tank built into the battery tray. 11. Install the battery and battery shield. 12. Connect the negative cable on the battery negative post. 13. Hook up a scan tool to initialize ABM and check for any faults. 14. Road test vehicle to ensure proper operation of brakes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Brake Module (MK25E) > Page 153 Electronic Brake Control Module: Service and Repair Controller Antilock Brake (MK20E) REMOVAL 1. Disconnect the battery cables. 2. Remove the battery. 3. Disconnect the vacuum hose connector at the tank built into the battery tray. 4. Remove the screw securing the coolant filler neck to the battery tray. 5. Remove the battery tray. CAB Connector Lock 6. Pull up on the CAB connector lock and disconnect the 24-way electrical connector. 7. Disconnect the pump/motor connector from the CAB. CAB Mounting Screws 8. Remove the screws securing the CAB to the HCU. 9. Pull CAB straight forward off HCU. INSTALLATION 1. Slide the CAB onto the HCU. 2. Install screws securing the CAB to the HCU. Tighten the mounting screws to 2 N.m (17 in lbs). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Brake Module (MK25E) > Page 154 3. Reconnect the 24-way wiring connector and the pump/motor wiring connector. 4. Install the battery tray. 5. Install the screw securing the coolant filler neck to the battery tray. 6. Reconnect the vacuum hose to the coolant tank built into the battery tray. 7. Install the battery. 8. Reconnect the battery cables. 9. Connect a DRBIII(R) to the vehicle. Check and clear any faults, and initialize the system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 161 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 162 Figure 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 163 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 164 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 165 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 166 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 167 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 168 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 169 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 170 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 171 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 172 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 173 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 174 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 175 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 176 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 177 Radiator Cooling Fan Motor Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and an Electrostatic Discharge Symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 178 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 179 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 180 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 181 Radiator Fan Realy (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 182 8w-42-20 (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 183 Radiator Cooling Fan Motor Relay: Description and Operation DESCRIPTION Fig.22 The radiator fan relay is a solid state type and is located on the front bumper reinforcement. OPERATION The solid state radiator fan relay is controlled by the Powertrain Control Module (PCM) by way of a Pulse Width Modulated (PWM) signal. The relay control circuit supplies a 12 volt signal to the PCM. The PCM then pulses the ground circuit to achieve fan on time. The relay provides a voltage to the fan motors which is proportional to the pulse width it receives from the PCM. The duty cycle ranges from 30% for low speed operation, then ramps-up to 100% for high speed operation. This fan control system provides infinitely variable fan speeds, allowing for improved fan noise, A/C performance, better engine cooling, and additional vehicle power. To control operation of the relay, the PCM looks at inputs from: ^ Engine coolant temperature ^ A/C pressure transducer ^ Ambient temperature from the body controller ^ Vehicle speed ^ Transmission oil temperature The PCM uses these inputs to determine when the fan should operate and at what speed. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 184 Radiator Cooling Fan Motor Relay: Testing and Inspection Test 1 - 3 SYMPTOM CHECKING RADIATOR FAN RELAY OUTPUT POSSIBLE CAUSES - Radiator Fan Relay Operation - Ground Circuit Open - Radiator Fan Relay Output Circuit - Radiator Fan Assembly Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 185 Radiator Cooling Fan Motor Relay: Service and Repair REMOVAL Fig.22 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Remove the radiator crossmember to front fascia closure panel. 4. Disconnect the relay electrical connector. 5. Remove the rivet attaching the relay to the front bumper beam. 6. Remove the relay. INSTALLATION CAUTION: The relay mounting location is designed to dissipate heat. Ensure the relay is securely attached to prevent relay "thermal" shutdown and relay damage, resulting in possible engine overheating. 1. Position relay and install a new rivet. 2. Connect electrical connector to relay. 3. Install closure panel and attaching screws. 4. Connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 190 Blower Motor Relay: Diagrams 8w-10-3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 191 8w-10-5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 192 Front Blower Motor Relay Rear Blower Motor Relay Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay: Description and Operation Front Front Blower Motor Relay The blower motor relay for the front heating-A/C system is an International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns. The front blower motor relay is located in the integrated power module (IPM) in the engine compartment. The front blower motor relay is an electromechanical switch that uses a low current input from the front control module (FCM) to control the high current output to the blower motor resistor (manual temperature control) or the blower motor power module (automatic temperature control). The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the blower motor. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The blower motor relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the blower motor relay include: - The common feed terminal (30) receives a battery current input from the battery through a B(+) circuit at all times. - The coil ground terminal (85) receives a ground input through the front/rear blower motor relay control circuit only when the FCM electronically pulls the control circuit to ground. - The coil battery terminal (86) receives a battery current input from the battery through a B(+) circuit at all times. - The normally open terminal (87) provides a battery current output to the blower motor resistor (manual temperature control) or blower motor power module (automatic temperature control) through a fuse in the IPM on the fused front blower motor relay output circuit only when the blower motor relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the blower motor relay coil is de-energized. The blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard relay and for complete HVAC wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front > Page 195 Blower Motor Relay: Description and Operation Rear Rear Blower Motor Relay The blower motor relay for the rear heating-A/C system is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns. The rear blower motor relay is located in the integrated power module (IPM) in the engine compartment. The rear blower motor relay is an electromechanical switch that uses a low current input from the front control module (FCM) to control the high current output to the rear blower motor resistor (manual temperature control) or rear blower motor power module (automatic temperature control). The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the rear blower motor. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear blower motor relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the rear blower motor relay include: - The common feed terminal (30) receives a battery current input from the battery through a B(+) circuit at all times. - The coil ground terminal (85) receives a ground input through the front/rear blower motor relay control circuit only when the FCM electronically pulls the control circuit to ground. - The coil battery terminal (86) receives a battery current input from the battery through a B(+) circuit at all times. - The normally open terminal (87) provides a battery current output to the blower motor resistor (manual temperature control) or blower motor power module (automatic temperature control) through a fuse in the IPM on the fused rear blower motor relay output circuit only when the rear blower motor relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the rear blower motor relay coil is de-energized. Refer to the appropriate wiring information for diagnosis and testing of the micro-relay and for complete HVAC wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair > Front Blower Motor Relay: Service and Repair Front REMOVAL 1. Disconnect and isolate the negative battery cable. Front Blower Motor Relay 2. Remove the cover from the integrated power module (IPM) located in the engine compartment. NOTE: Refer to the fuse and relay map on the IPM cover for front blower motor relay location. 3. Remove the front blower motor relay from the IPM. INSTALLATION NOTE: Refer to the fuse and relay map on the cover of the integrated power module (IPM) for front blower motor relay location. 1. Position the front blower motor relay to the proper receptacle in the IPM. 2. Align the front blower motor relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair > Front > Page 198 Blower Motor Relay: Service and Repair Rear REMOVAL 1. Disconnect and isolate the negative battery cable. Rear Blower Motor Relay 2. Remove the cover from the integrated power module (IPM). NOTE: Refer to the fuse and relay map on the IPM cover for rear blower motor relay location. 3. Remove the rear blower motor relay from the IPM. INSTALLATION NOTE: Refer to the fuse and relay map on the cover of the integrated power module (IPM) for rear blower motor relay location. 1. Position the rear blower motor relay to the proper receptacle in the IPM. 2. Align the rear blower motor relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 202 Compressor Clutch Relay: Diagrams 8w-10-3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 203 8w-10-5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 204 A/C Compressor Clutch Relay 2002-06 Mini Vans A/C Compressor Clutch 2003 Voyager, Caravan Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 205 Compressor Clutch Relay: Description and Operation A/C Compressor Clutch Relay The A/C clutch relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The A/C clutch relay is located in the integrated power module (IPM) in the engine compartment. The ISO-standard A/C clutch micro-relay is an electromechanical switch that uses a low current input controlled by the powertrain control module (PCM) to control the high current output to the A/C clutch field coil. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the A/C clutch field coil. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The A/C clutch relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the A/C compressor clutch relay include: - The common feed terminal (30) receives a battery current input from a fuse in the IPM through a fused B(+) circuit at all times. - The coil ground terminal (85) receives a ground input from the PCM through the compressor clutch relay control circuit only when the PCM electronically pulls the control circuit to ground. - The coil battery terminal (86) receives a battery current input from the PCM through a fused ignition switch output (run-start) circuit only when the ignition switch is in the On or Start positions. - The normally open terminal (87) provides a battery current output to the compressor clutch coil through the compressor clutch relay output circuit only when the compressor clutch relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the compressor clutch relay coil is de-energized. The A/C clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard micro-relay and for complete HVAC wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 206 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. A/C Compressor Clutch Relay 2. Remove the cover from the integrated power module (IPM) located in the engine compartment. NOTE: Refer to the fuse and relay map on the inside of the IPM cover for A/C compressor clutch relay location. 3. Remove the A/C compressor clutch relay from the IPM. INSTALLATION NOTE: Refer to the fuse and relay map on the inside of the integrated power module (IPM) cover for A/C compressor clutch relay location. 1. Position the A/C compressor clutch relay into the receptacle in the IPM. 2. Align the A/C compressor clutch relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams Control Module HVAC: Diagrams Front Blower Module C1 (ATC) Front Blower Module C2 (ATC) Rear Blower Motor Power Module C1 (3 Zone ATC) Rear Blower Motor Power Module C2 (3 Zone ATC) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Front Control Module HVAC: Description and Operation Front Front Blower Power Module A front blower motor power module is used on this model when it is equipped with the automatic temperature control (ATC) heating-A/C system. Models equipped with the manual temperature control (MTC) heating-A/C system use a blower motor resistor, instead of the blower motor power module. The front blower motor power module is mounted to the rear of the front HVAC housing, directly behind the glove box. The blower motor power module consists of a molded plastic mounting plate with two integral connector receptacles (1). Concealed behind the mounting plate is the power module electronic circuitry and a large finned heat sink (2). The front blower motor power module is accessed for service by removing the glove box. The front blower motor power module is connected to the vehicle electrical system through a dedicated lead and connector of the front HVAC wire harness. A second connector receptacle receives the wire harness connector from the front blower motor. The front blower motor power module allows the microprocessor-based automatic temperature control (ATC) A/Cheater control to calculate and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a pulse width modulated (PWM) circuit strategy. The PWM voltage is applied to a comparator circuit which compares the PWM signal voltage to the front blower motor feedback voltage. The resulting output drives the power module circuitry, which provides a linear output voltage to change or maintain the desired blower speed. The front blower motor power module is diagnosed using a DRBIII(R) scan tool. The front blower motor power module cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Front > Page 212 Control Module HVAC: Description and Operation Rear Rear Blower Motor Power Module A rear blower motor power module is used on this model when it is equipped with the automatic temperature control (ATC) heating-A/C system.Models equipped with the manual temperature control (MTC) heating-A/C system use a blower motor resistor, instead of the blower motor power module. The rear blower motor power module is installed in the back of the rear HVAC housing, directly above the A/C expansion valve. The power module consists of a molded plastic mounting plate with two integral connector receptacles. Concealed behind the mounting plate is the power module electronic circuitry and a large finned heat sink. The rear blower motor power module is accessed for service by removing the right quarter and D-pillar trim panels. The rear blower motor power module is connected to the vehicle electrical system through a dedicated lead and connector of the rear HVAC wire harness. A second connector receptacle receives the wire harness connector from the rear blower motor. The rear blower motor power module allows the microprocessor-based automatic temperature control (ATC) A/Cheater control to calculate and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a pulse width modulated (PWM) circuit strategy. The PWM voltage is applied to a comparator circuit which compares the PWM signal voltage to the rear blower motor feedback voltage. The resulting output drives the power module circuitry, which adjusts the voltage output received from the rear blower motor relay to change or maintain the desired blower speed. The rear blower motor power module is diagnosed using a DRBIII(R) scan tool. The rear blower motor power module cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module Control Module HVAC: Service and Repair Front Blower Motor Power Module REMOVAL WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. - THE HEAT SINK FOR THE BLOWER MOTOR POWER MODULE MAY GET VERY HOT DURING NORMAL OPERATION. IF THE BLOWER MOTOR WAS TURNED ON PRIOR TO SERVICING THE BLOWER MOTOR POWER MODULE, WAIT FIVE MINUTES TO ALLOW THE HEAT SINK TO COOL BEFORE PERFORMING DIAGNOSIS OR SERVICE. FAILURE TO TAKE THIS PRECAUTION CAN RESULT IN POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the negative battery cable. 2. Remove the glove box from the instrument panel. 3. Disconnect the two wire harness connectors from the front blower motor power module. Front Blower Motor Power Module 4. Remove the two screws that secure the front blower motor power module to the front HVAC housing and remove the power module. INSTALLATION 1. Position the front blower motor power module into the front HVAC housing. 2. Install the two screws that secure the front blower motor power module to the front HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.). 3. Connect the two wire connectors to the front blower motor power module. 4. Install the glove box. 5. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module > Page 215 Control Module HVAC: Service and Repair Rear Blower Motor Power Module REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel. Rear Blower Motor Power Module 3. Disconnect the rear HVAC wire harness connector from the rear blower motor power module. 4. Disconnect the rear blower motor wire harness connector from the rear blower motor power module. 5. Remove the two screws that secure the rear blower motor power module to the rear HVAC housing and remove the power module. INSTALLATION 1. Position the rear blower motor power module into the rear HVAC housing. 2. Install the two screws that secure the rear blower motor power module to the rear HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.). 3. Connect the rear blower motor wire harness to the rear blower motor power module. 4. Connect the rear HVAC wire harness connector to the rear blower motor power module. 5. Install the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel. 6. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Description and Operation Turn Signal Relay: Description and Operation The turn signal flasher function is incorperated into the Body Control Module (BCM), for further information, refer to Body Control Module for wiring diagrams and Powertrain Management/ Computers and Control Systems/ System Diagnosis/ Diagnostic Trouble Code Tests and Associated Procedures/ Manufacturer Code Charts/ Exterior Lighting. See: Relays and Modules Powertrain Management/Relays and Modules - Computers and Control Systems/Body Control Module See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Exterior Lighting Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component Locations > Page 237 Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 238 Front Control Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) and the Front Control Module (FCM). The IPM is located in the engine compartment, next to the battery.The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. This IPM connects directly to the battery positive through a four pin connector. The ground connection is through two other connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. All of the current from the battery and the generator output enters the Integrated Power Module (IPM) through a four pin connector on the bottom of the module. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 241 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is an electrical control and interface center located in the engine compartment. When it is mated to the Power Distribution Center (PDC), it is referred to as the Integrated Power Module (IPM). The IPM, with its fuses and relays provides power and signal distribution throughout most of the vehicle. The FCM receives both hard wire and digital electronic inputs from the vehicle electrical system through the PDC. Based on these inputs and the ignition switch position, it provides direct power feeds and relay control to some of the vehicles most critical electrical systems. The Front Control Module provides the following features: Controlled power feeds: - Front airbag system - Headlamp power - EATX module power (4 speed only) - Front washer motor - Rear washer motor - Cabin Heater - Brake shift interlock system Relay controls: - Fog lamp relay (when equipped) - Park lamp relay - Front wiper on relay - Front wiper high/low relay - Accessory relay - Horn relay - Front & rear blower relay - Name brand speakers (NBS) relay - Adjustable pedals relay (non-memory) - Electronic back light (EBL) run only relay Electrical inputs: - Headlamp battery supplies 1 & 2 - Module battery supply - Power ground - Ignition switch RUN or START position status - Ignition switch START only status - PCI Bus - Stop lamp switch - Horn switch - Back-up switch - Wiper park switch - Washer fluid level switch - Brake fluid level switch - Ambient temperature sensor - Right park lamp outage - Left park lamp outage - Battery IOD - Battery (+) connection detection - Flash reprogramming voltage CONTROLLED POWER FEEDS Front airbag system The FCM provides power to the Occupant Restraint Control (ORC) system through two fuseless circuits (ORC RUN/START, and ORC RUN only). These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied while the ignition switch is in the RUN and START positions on pin 48 of the FCM connector, and in the RUN only position on pin 29. Headlamp power The headlamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a headlamp switch status change. The FCM then turns on power to the headlamps through four fuseless circuits. These circuits are electronically controlled and continuously monitored for malfunctions.Power is supplied to each filament in a separate circuit. For vehicles equipped with Daytime Running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination. EATX power The electronic automatic 4 speed transmission module is powered when the ignition switch is in the UNLOCK, RUN or START positions. This circuit is Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 242 electronically controlled and continuously monitored for malfunctions. Power is supplied through pin 27 of the FCM connector. Front washer motor The front washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The front washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition, the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Rear washer motor The rear washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The rear washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition,the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Cabin Heater When the ignition is in Run, the FCM monitors the PCI bus for the Cabin Heater Activation request. The Automatic or Manual Temperature Control initiates this request only when all conditions for the Cabin Heater activation are favorable. The request carries the status bit that the FCM requires to activate its Cabin Heater Assist Control output. This output is a low side driver (coming from FCM pin 15) which supplies a ground signal to the Cabin Heater (pin 5). When the Cabin Heater receives this ground signal input, it interprets this as an activation signal. The FCM low side driver is also capable of diagnostic sensing. The driver will sense an open circuit when the driver is off, and will sense a short to voltage when the driver is on. The FCM will set DTC's for both of these types of faults. For additional information, refer to Cabin Heater under General Information and Diagnostic Procedures. Brake shift interlock system The brake shift interlock solenoid receives power from both high side and low side controls inside the FCM. The high side control is on the same circuit as the EATX module power, and the low side control comes through pin 47 of the FCM connector. The solenoid is controlled by the low side driver when the brake pedal is pressed. Both circuits are continuously monitored for malfunctions. RELAY CONTROLS Fog lamp relay The fog lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the fog lamp relay. The fog lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Fog lamp functionality is not equipped on all vehicles. The FCM learns that the vehicle is equipped with fog lamps by reading the BCM PCI Bus message. Park lamp relay The park lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the park lamp relay. The park lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper on relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper on relay. The front wiper on relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper high/low relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper high/ low relay. The relay switches power between the low speed and high speed windings of the wiper motor. The front wiper high/low relay is powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Accessory relay The accessory relay works in conjunction with the FCM's power accessory delay feature to control the operation of the radio, power windows, washer motors,wiper motors and power outlet. The accessory relay is turned on through low side control on pin 35 of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Depending on the ignition switch position, the accessory relay will remain on or will time-out and turn off. The accessory relay remains on in the RUN and ACCY positions of the ignition switch. In the UNLK and OFF positions, the relay will remain energized for 45 seconds then turn off. During this time-out period, if the driver or passenger doors are opened, the relay will turn off immediately. While the ignition switch is in the START position, the relay will also drop-out, then resume operation. Accessory relay operation is most Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 243 noticeable by observing the operation of the radio or blower functions. Horn relay The horn relay operates through a direct wire input to the FCM from the horn switch (FCM pin 17) , or a PCI Bus message from the BCM. The relay responds to the horn switch, remote door lock and VTA alarm functions. The horn relay is powered through low side control on pin 10 of the FCM. Under normal operating conditions, if the horn is pressed for longer than 30 seconds, the FCM will automatically deactivate the horn to prevent damage to it. The FCM will re-activate control of the relay after a 25 second cool-down period. This circuit is electronically controlled and continuously monitored for malfunctions. Front and rear blower relay RS with MTC Upon ignition on, the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus.The front blower relay and the rear blower relay, if equipped, are then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. RG with MTC Upon power up (Power switch on), the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus. The front blower relay is then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. Name Brand Speakers (NBS) relay The NBS relay operates through the vehicle bus interface between the radio and the FCM. When the radio is turned on, the radio sends a PCI Bus message to the FCM. The NBS relay is then powered on through low side control on pin 11 of the FCM. The relay supplies power to the amplified speaker, and ground is supplied through the radio. This circuit is electronically controlled and continuously monitored for malfunctions. Electronic Back Light (EBL) relay The rear defrost switch is part of the Automatic Temperature Control or A/C-Heater Control Module (Manual Temp). When the ignition switch is in the RUN position and the rear defrost switch is turned on, the ATC or A/C-Heater Control Module sends a PCI Bus message to the FCM. The EBL run only relay is then powered through low side control on pin 31 of the FCM. The relay provides the high side to the rear window defrost grid, and ground is attached to the vehicle body. The FCM will only allow the rear defrost to operate in the RUN position. This circuit is electronically controlled and continuously monitored for malfunctions. Adjustable Pedals Relay (Non-Memory) The Adjustable Pedals Relay is only on nonmemory Adjustable Pedals System equipped vehicles. The relay is supplied battery voltage from the IPM and is electronically controlled with a low side driver within the FCM. The relay is energized when the transmission is in reverse and when cruise control operation is engaged. This action disables the Adjustable Pedals System from movement. This circuit is continuously monitored for proper function. ELECTRICAL INPUTS Headlamp battery supplies 1 & 2 - 12 volt input on pins 1 and 2. Battery supply voltage for switching headlamp circuits only. Module battery supply - 12 volt input on pin 9. Battery supply voltage for all other FCM operations. Power ground - Ground source on pin 8 for all FCM operations. Ignition switch RUN or START position status - 12 volt input on pin 37. Allows the FCM to determine the ignition switch status for related FCM operations. PCI Bus - Approximately 7.5 volt input on pin 22. Allows the FCM to communicate with other modules on the vehicle bus. Stop lamp Switch status - 12 volt input on pin 44. Provides for brake shift interlock function. Horn Switch - Ground input on pin 17. Primary means for engaging the horn. Back-up switch - Ground input on pin 39. Input is converted to a PCI Bus status message for use by other modules. Wiper park switch - Ground input on pin 16. Used to determine park placement of wipers. Also used as feedback to FCM to determine correct operating mode of wipers. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 244 Washer fluid level switch - Ground input to pull-up on pin 18. Ground is switched into the circuit when washer bottle fluid level is low. Brake fluid level switch - Ground input to pull-up on pin 36. Ground is switched into the circuit when brake fluid level is low. Ambient temperature sensor - Resistive input to pull-up on pin 25. Corresponding voltage level is converted to a PCI Bus message for use by other modules on the bus. Right park lamp outage - 12 volt input on pin 21. Used to determine if right park lamp circuit is operating properly. Left park lamp outage - 12 volt input on pin 41. Used to determine if left park lamp circuit is operating properly. Battery IOD - 12 volt input on pin 20. The FCM enters a low power consumption mode when the ignition is turned OFF. This low current draw battery supply keeps the microprocessor functioning in the low power mode. Battery (+) connection detection - 12 volt input on pin 38. The battery connection on the PDC incorporates the use of an internal switch to determine if the connector is properly mated and the Connector Positive Assurance (CPA) is engaged. If the CPA is not properly engaged, a voltage on pin 38 will be interpreted as an unseated connector and a fault will set. Flash programming voltage - 20 volt input on pin 42. When a DRBIII(R) is connected and the proper flash reprogramming sequence is selected, the 20 volt signal will be applied through pin 42. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 245 Power Distribution Module: Testing and Inspection The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any front control module related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool, such as the DRB III(R). The most reliable, efficient, and accurate means to diagnose the front control module requires the use of a DRB III(R) scan tool and the proper Body Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. For information regarding Trouble Code Diagnostic Charts for this system, please refer to Body Control Module testing. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect the negative and positive battery cables. 2. Remove the battery thermal guard. 3. Remove the battery. Integrated Power Module 4. Using a flat-bladed screwdriver, twist the Integrated Power Module (IPM) bracket retaining latch outward to free the IPM from its mounting bracket Disconnecting IPM 5. Rotate the IPM counter-clockwise to access and disconnect the electrical connectors. 6. Remove the IPM bracket clips from the hinge. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 248 1. Snap the left side of the Integrated Power Module (IPM) housing in its mounting bracket and connect the various electrical connectors. NOTE: Ensure that the Connector Positive Assurance (CPA) on the five-pin B+ connector is positively engaged to prevent generating a Diagnostic Trouble Code (DTC). 2. Rotate the IPM clock-wise until secured in mounting bracket. An audible click may be heard. 3. Install the battery. 4. Install the battery thermal guard. 5. Connect the negative and positive battery cables. 6. Using a scan tool, check for any stored diagnostic trouble codes. Ensure that all vehicle options are operational. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 249 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the negative and positive battery cables from the battery. 2. Remove the battery. Removing Integrated Power Module 3. Using a long flat-bladed screwdriver, gently twist the Integrated Power Module (IPM) retaining clip outboard to free the IPM from its mounting bracket. Rotate IPM upward to access the Front Control Module (FCM) retaining screws. 4. Remove the front control module retaining screws. Front Control Module 5. Pull the FCM straight from the IPM assembly to disconnect the electrical connector and remove the FCM from the vehicle. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 250 NOTE: Front Control Module must be programmed to the correct radio EQ curve using the DRB III(R). This will ensure that the audio system is operating correctly. 1. Install the Front Control Module (FCM) in the Integrated Power Module (IPM) assembly by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 1 N.m (7 in. lbs). 3. Rotate the IPM assembly downward to secure in mounting bracket. 4. Install the battery in the vehicle. 5. Connect the positive and negative battery cables. 6. Using the DRB III(R), under "FRONT CONTROL MODULE" then "MISC" program the EQ curve of the radio into the Front Control Module. NOTE: If the vehicle is not equipped with Name Brand Speakers (Infinity, etc.) or Headlamp Washers the DRB IIIT must be used to Disable the appropriate relays in the Integrated Power Module Assembly Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 255 Relay Box: Locations Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 256 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 257 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 258 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 259 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 260 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 261 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 262 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 263 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 264 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 265 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 268 Relay Box: Application and ID Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 269 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 270 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 271 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 272 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 273 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 274 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 275 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 276 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 277 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set Body Control Module: Customer Interest Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set NUMBER: 08-028-05 GROUP: Electrical DATE: May 28, 2005 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD JULY, 2005. SUBJECT: Flash: MIL Illumination, Remote Keyless Entry (RKE) Inoperative OVERVIEW: This bulletin involves reprogramming the Body Control Module (BCM) with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to CS vehicles built on or before May 7, 2005 (MDH 0507XX) and RS vehicles, built on or between July 26, 2004 (MDH 0726XX) through and including May 7, 2005 (MDH 0507XX), with a 4-connector BCM. SYMPTOM/CONDITION: ^ MIL Illumination ^ RKE inoperative ^ PCI Internal Fault DTC in BCM DIAGNOSIS: 1. With the ignition switch in the "RUN" position, determine the original software part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R)" standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 288 g. Record the "Software part # " on the repair order for later reference. h. Check DTC's 2. If the Symptom/Condition is present, use the following table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "BCM part # ", recorded in "Diagnosis Step # 1, in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 4. Select the flash file. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 289 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm Body Control Module: Customer Interest Electrical - Locks Inoperative/Liftgate Triggers Alarm NUMBER: 08-040-04 GROUP: Electrical DATE: December 9, 2004 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD FEBRUARY, 2005. SUBJECT: Flash: Driver And Passenger Power Door Lock Switches Inoperative And Opening the Liftgate Triggers The Theft Alarm OVERVIEW: This bulletin involves selectively erasing and reprogramming the Body Control Module (BCM) with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to 2005 vehicles equipped with Power Locks only (sales code JPB) and 2004 2005 vehicles equipped with Power Locks, Power Liftgate, and Security Alarm (sales codes JPB, JRC and LSA respectively). SYMPTOM/CONDITION: The vehicle operator may describe: ^ The alarm sounds erroneously when opening the power liftgate using the key fob while the Vehicle Theft Alarm (VTA) is armed. ^ The driver's and/or passenger's door lock switches are inoperative. The technician may find "Left Unlock Output Failure" and/or "Right Unlock Output Failure" Diagnostic Trouble Codes (DTC's) in the BCM. DIAGNOSIS: 1. Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. With the ignition switch in the "RUN" position, determine the original part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" g. Record the "Software part # " on the repair order for later reference. h. Check DTC's Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm > Page 294 3. If the vehicle operator describes or experiences the Symptom/Condition, use the table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "Software part # " recorded during "Diagnosis" in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 4. Select the calibration. 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm > Page 295 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition to the "Run" position (engine not running). 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. 13. Verify that the problem cannot be repeated by cycling the ignition switch OFF/ON and actuating both door lock switches a few times. If any door lock failure still persists then further diagnosis is necessary. Verify the BCM "Software p/n" was updated to the new software p/n using Diagnosis Step # 2. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, PCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set Body Control Module: All Technical Service Bulletins Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set NUMBER: 08-028-05 GROUP: Electrical DATE: May 28, 2005 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD JULY, 2005. SUBJECT: Flash: MIL Illumination, Remote Keyless Entry (RKE) Inoperative OVERVIEW: This bulletin involves reprogramming the Body Control Module (BCM) with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to CS vehicles built on or before May 7, 2005 (MDH 0507XX) and RS vehicles, built on or between July 26, 2004 (MDH 0726XX) through and including May 7, 2005 (MDH 0507XX), with a 4-connector BCM. SYMPTOM/CONDITION: ^ MIL Illumination ^ RKE inoperative ^ PCI Internal Fault DTC in BCM DIAGNOSIS: 1. With the ignition switch in the "RUN" position, determine the original software part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R)" standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 301 g. Record the "Software part # " on the repair order for later reference. h. Check DTC's 2. If the Symptom/Condition is present, use the following table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "BCM part # ", recorded in "Diagnosis Step # 1, in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 4. Select the flash file. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 302 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm Body Control Module: All Technical Service Bulletins Electrical - Locks Inoperative/Liftgate Triggers Alarm NUMBER: 08-040-04 GROUP: Electrical DATE: December 9, 2004 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD FEBRUARY, 2005. SUBJECT: Flash: Driver And Passenger Power Door Lock Switches Inoperative And Opening the Liftgate Triggers The Theft Alarm OVERVIEW: This bulletin involves selectively erasing and reprogramming the Body Control Module (BCM) with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to 2005 vehicles equipped with Power Locks only (sales code JPB) and 2004 2005 vehicles equipped with Power Locks, Power Liftgate, and Security Alarm (sales codes JPB, JRC and LSA respectively). SYMPTOM/CONDITION: The vehicle operator may describe: ^ The alarm sounds erroneously when opening the power liftgate using the key fob while the Vehicle Theft Alarm (VTA) is armed. ^ The driver's and/or passenger's door lock switches are inoperative. The technician may find "Left Unlock Output Failure" and/or "Right Unlock Output Failure" Diagnostic Trouble Codes (DTC's) in the BCM. DIAGNOSIS: 1. Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. With the ignition switch in the "RUN" position, determine the original part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" g. Record the "Software part # " on the repair order for later reference. h. Check DTC's Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm > Page 307 3. If the vehicle operator describes or experiences the Symptom/Condition, use the table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "Software part # " recorded during "Diagnosis" in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 4. Select the calibration. 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm > Page 308 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition to the "Run" position (engine not running). 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. 13. Verify that the problem cannot be repeated by cycling the ignition switch OFF/ON and actuating both door lock switches a few times. If any door lock failure still persists then further diagnosis is necessary. Verify the BCM "Software p/n" was updated to the new software p/n using Diagnosis Step # 2. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, PCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 311 Body Control Module: Connector Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 312 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 313 Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 316 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 317 Figure 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 318 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 319 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 320 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 321 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 322 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 323 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 324 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 325 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 326 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 327 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 328 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 329 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 330 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 331 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 332 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and an Electrostatic Discharge Symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 333 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 334 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 335 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 336 Body Control Module: Connector Views Body Control Module C1 Body Control Module C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 337 Body Control Module C3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 338 Body Control Module C4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 339 Body Control Module C5 (early Build) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 340 Body Control Module: Electrical Diagrams Non-memory Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 341 Memory Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 342 Occupant Restraint Controller - Highline Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 343 Occupant Restraint Controller - Lowline Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 344 Occupant Classification System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 345 Premium Audio System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 346 Base Audio System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 347 CD Changer DVD/CD Changer Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 348 Remote Radio Controls Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 349 Front ATC - LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 350 Front ATC - RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 351 Rear ATC - Three Zone Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 352 Diesel Cabin Heater Assist (DCHA) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 353 Communication Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 354 PCM Communication - NGC ECM And Cabin Heater Assist Communication - Diesel Only Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 355 Door Ajar System With Power Sliding Doors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 356 Door Ajar System Without Power Sliding Doors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 357 Exterior Lighting Horn System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 358 Ignition Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 359 Integrated Power Module/body Control Module Power And Grounds Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 360 Instrument Cluster - Base Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 361 Instrument Cluster And Message Center (export, LHD) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 362 Instrument Cluster And Message Center (export,RHD) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 363 Interior Lighting Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 364 Base Manual Temperature Control System, LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 365 Base Manual Temperature Control System. RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 366 Dual-zone And Three Zone(front) Manual Temperature Control System, LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 367 Dual-zone Zone(front) Manual Temperature Control System, RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 368 Three Zone Rear Manual Temperature Control System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 369 Front Blower Motor - RS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 370 Front Blower Motor - RG Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 371 Rear Blower Motor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 372 Memory System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 373 Overhead Console Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 374 Park Assist Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 375 Power Door Looks/RKE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 376 LHD (export Only) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 377 RHD (export Only) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 378 Power Liftgate System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 379 Lift Power Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 380 Right Power Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 381 Power Sliding Door And Liftgate Switches Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 382 Rear Defog/Heated Mirror Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 383 Hands Free Phone - With CD Changer Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 384 Hands Free Phone - With CD/DVD Changer Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 385 Vehicle Theft Security System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 386 Thatcam Alarm System (export Only) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 387 Wipers - Front And Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 388 A/C - Lef Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 389 Le - Tr 8W-45-2 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 390 8w-45-2 Next Diagram See: 8W-45-3 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-3 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 391 8w-45-3 Next Diagram See: 8W-45-4 Previous Diagram See: 8W-45-2 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 392 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-4 Next Diagram See: 8W-45-5 Previous Diagram See: 8W-45-3 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 393 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-5 Next Diagram See: 8W-45-6 Previous Diagram See: 8W-45-4 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 394 8W-45-6 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-6 Next Diagram See: 8W-45-7 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 395 Previous Diagram See: 8W-45-5 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-7 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 396 8w-45-7 Next Diagram See: 8W-45-8 Previous Diagram See: 8W-45-6 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-8 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 397 8w-45-8 Next Diagram See: 8W-45-9 Previous Diagram See: 8W-45-7 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 398 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-9 Next Diagram See: 8W-45-10 Previous Diagram See: 8W-45-8 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 399 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-10 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 400 Next Diagram See: 8W-45-11 Previous Diagram See: 8W-45-9 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-11 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 401 8w-45-11 Next Diagram See: 8W-45-12 Previous Diagram See: 8W-45-10 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-12 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 402 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-12 Next Diagram See: 8W-45-13 Previous Diagram See: 8W-45-11 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 403 Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-13 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-13 Next Diagram See: 8W-45-14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 404 Previous Diagram See: 8W-45-12 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-14 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 405 8w-45-14 Next Diagram See: 8W-45-15 Previous Diagram See: 8W-45-13 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 406 8W-45-15 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-15 Next Diagram See: 8W-45-16 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 407 Previous Diagram See: 8W-45-14 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-16 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 408 8w-45-16 Next Diagram See: 8W-45-17 Previous Diagram See: 8W-45-15 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-17 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 409 8w-45-17 Next Diagram See: 8W-45-18 Previous Diagram See: 8W-45-16 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-18 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-18 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 410 Next Diagram See: 8W-45-19 Previous Diagram See: 8W-45-17 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-19 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 411 8w-45-19 Next Diagram See: 8W-45-20 Previous Diagram See: 8W-45-18 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-20 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 412 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-19 Previous Diagram See: 8W-45-19 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 413 Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced as an assembly only. Attempting to remove or repair certain system subcomponents may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 416 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description Body Control Module: Description and Operation System Description IDENTIFICATION OF SYSTEM The vehicle systems that are part of the body system are: - Adjustable Pedal System (APS) - Airbag System - Audio - Automatic Temperature Control - Cabin Heater - Chime - Communication - Door Ajar System - Electrically heated system - Exterior lighting - Instrument Cluster - Interior Lighting - Manual Temperature Control - Memory Seat - Overhead Console - Park Assist - Power Door Lock/RKE - Power Folding Mirrors - Power Sliding Doors - Power Liftgate - Power windows - Telecommunications (hands free phone) - Tire Pressure Monitor System (TPMS) - Vehicle Theft Security System (VTSS) - Windshield Wiper and Washer SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 2005 RS and RG consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate modules. All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages addressed to it through binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the Communication Section of this general information. The Body Control Module (BCM) is located in the passenger compartment, attached to the bulkhead underneath the left side of the instrument panel. The BCM utilizes integrated circuitry and information carried on the Programmable Communications Interface (PCI) data bus network along with many hard wired inputs to monitor many sensor and switch inputs throughout the vehicle. In response to those inputs, the internal circuitry and programming of the BCM allow it to control and integrate many electronic functions and features of the vehicle through both hard wired outputs and the transmission of electronic message outputs to other electronic modules in the vehicle over the PCI data bus. The Body Control Module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the BCM is interfaced to the vehicle's serial bus communications network, referred to as the Programmable Communications Interface (PCI) bus. This network consists of the; - Powertrain Control Module (PCM) - Transmission Control Module (TCM) - Mechanical Instrument Cluster (MIC) - Occupant Restraint Controller (ORC) - Compass/Mini-Trip Computer (CMTC) - Electronic Vehicle Information Center (EVIC) - Controller Antilock Brake (CAB) - HVAC Control Module - Sliding Door Control Modules (driver and passenger side doors) - Power Liftgate Module (PLG) - Audio system equipped with RAZ, RBU, RBK, and RBB radios. - Sentry Key Remote Entry Module (SKREEM). - Side Impact Airbag Control Module (SIACM) - Memory Seat Module (MSM) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 419 - Sentry Key Immobilizer Module (SKIM) The BCM is operational when battery power is supplied to the module. The BCM provides the following features: - Power Door Locks - Automatic Door Locks - Battery Protection - The BCM will automatically turn off all exterior lamps after 3 minutes, and all interior lamps after 15 minutes after the ignition is turned off, if they are not turned off by the driver. - Chime Control - Compass/Mini-Trip support. - Interior Lighting (Courtesy/Reading Lamps) - BCM Diagnostic Reporting - Electronic Liftgate Release (with Power Door Locks) - Exterior Lighting - Headlamp Time Delay (with/without Automatic Headlamps) - Illuminated Entry - Fade to Off Interior Lamps - This feature dims the interior lighting (courtesy lamps) gradually if the BCM does not receive any new inputs that would cause the interior lamps to remain on. - Pulse Width Modulated Instrument Panel Dimming - Door Lock Inhibit - This feature disables the door lock functions if the key is in the ignition and either front door is ajar. Pressing the Remote Keyless Entry (RKE) lock/unlock button under these conditions result in normal lock/unlock activation. Learned Features The BCM has the ability to LEARN additional features in the vehicle, provided the appropriate switch input and PCI data bus messages are received. Refer to the LEARNED FEATURES table. When replacing a BCM there are three modules available: - Base - Midline - RG - Export Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 420 The Midline controller is used on vehicles that have Power Door Locks. If a vehicle is equipped with the Vehicle Theft Security System, the Midline controller becomes a Premium when the theft feature is enabled. CAUTION: Do not swap Body Control Modules between vehicles or body controller's off the shelf. The BCM has internal diagnostic capability that assists in diagnosing the system error. When an OPEN or a SHORT circuit exists, the diagnostic tool can be used to read the BCM faults. The faults are very descriptive in identifying the appropriate feature that has faulted. The only two faults that the BCM logs that conclude the replacement of a BCM are faults; - # 01 - Internal BCM failure (replace BCM) - # 1F - J1850 Internal Hardware Failure (replace BCM) Otherwise the appropriate diagnostic procedures for each of the features should be taken when the BCM logs a fault. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 421 Body Control Module: Description and Operation Functional Operation Adjustable Pedals System The Adjustable Pedals are designed to enable the fore and aft repositioning of the brake and accelerator pedals. This results in improved ergonomics in relation to the steering wheel for taller and shorter drivers. Being able to adjust the pedal positions also allows the driver to set steering wheel tilt and seat positions to the most comfortable position available. The positions can be adjusted without compromising safety or comfort in actuating the pedals. Repositioning the pedals does not change the effort required for actuation. Changing of pedal position is accomplished by means of a motor. Operating the adjustable pedal switch activates the pedal drive motor. The pedal drive motor changes the position of the brake and accelerator pedals. The pedal can move rearward or forward. The pedals are moved to a position that is most comfortable for the driver. The accelerator and brake pedals are moved at the same rate to ensure synchronization. Neither the motor nor mechanisms are subject to mechanical stress of brake or accelerator application. The adjustable pedals feature is available on a non-memory/memory-equipped vehicle. The non-memory system consists of a mechanical switch that allows pedal travel adjustment. The IPM controls the Fused B+ circuit voltage to the adjustable pedals switch through the adjustable pedals relay. The circuit opens when the IPM detects an active cruise control state or when the vehicle is in reverse. The adjustable pedals control switch is located on the right side steering column shroud. The switch is hardwired directly to the adjustable pedals motor. When the operator actuates the switch to adjust the pedals, voltage is applied to the adjustable pedals motor allowing adjustment. The memory system, known as the Memory Seat Mirror Adjustable Pedal Module (MSMAPM), is located under the driver's seat and controls the adjustable pedals. The adjustable pedals control switch is located on the right side steering column shroud. The switch is hardwired directly to the MSMAPM. When the operator actuates the switch to adjust the pedals, the MSMAPM controls the adjustable pedals motor movement with input from the adjustable pedals sensor. This sensor allows pedal adjustment and memory functions to be recalled from the driver door mounted memory buttons or the RKE transmitters. The adjustable pedals will not operate when in an active cruise control state or when the vehicle is in reverse. Part 1 of 2 AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM AND OCCUPANT CLASSIFICATION SYSTEM The Airbag System contains the following components: Occupant Restraint Controller (ORC), Air-bag Warning Indicator, Clockspring, Driver and Passenger dual squib Airbags, Driver and Passenger Seat belt Tensioner (SBT), Driver and Passenger Hall-effect Seat Belt Buckle Switches (SBS), Left and Right Side Curtain Airbags, and Front and Side Impact Sensors. The ORC also monitors the Occupant Classification System (OCS) for the presence of a passenger in the front outer seat. The Occupant Classification System contains the following components: Occupant Classification Module (OCM), Bladder and Sensor, Belt Tension Sensor, and Passenger Airbag off Indicator. The Occupant Restraint Controller (ORC) supports staged airbag deployment and remote impact sensing. Staged deployment is the ability to trigger airbag system squib inflators individually as needed to provide the appropriate restraint for the severity of the impact. The ORC has four major functions: PCI Bus communications, onboard diagnostics, impact sensing, and component deployment. The ORC also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the front airbag components for two seconds following a battery disconnect or failure during an impact. The ORC is secured to the floor panel transmission tunnel below the instrument panel inside the vehicle. The ORC cannot be repaired or adjusted. The ORC sends and/or receives PCI Bus messages with the Instrument Cluster (MIC), Body Control Module (BCM), and Powertrain Control Module (PCM). Diagnostic trouble codes will be set if the communication with these modules is lost or contains invalid information. The microprocessor in the ORC monitors the front impact sensor signals and the airbag system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sends a message to the instrument cluster via PCI bus to turn on the Airbag Warning Indicator. The ORC can set both active and stored diagnostic trouble codes to aid in diagnosing system problems. See DIAGNOSTIC TROUBLE CODES. The ORC uses an internal accelerometer, two front sensors and six side impact sensors, to sense the rate of vehicle deceleration and provide verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ORC microprocessor determines when the deceleration rate is severe enough to require airbag system protection. The ORC also uses the driver and passenger seat belt switch status (buckled or unbuckled) to determine the level of driver airbag deployment, low medium or high. When the programmed conditions are met, the ORC sends an electrical signal to deploy the appropriate airbag system components. WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS CAN RESULT IS ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. - NEVER STRIKE OR KICK THE OCCUPANT RESTRAINT CONTROLLER, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. The Airbag Warning Indicator is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 422 turned to the run or start position, the ORC performs a lamp check by turning the Airbag Warning Indicator on for 6-8 seconds. After the lamp check, if the indicator turns off, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes off, there is usually an intermittent problem in the system. DRIVER AIRBAG The airbag protective trim cover is the most visible part of the driver side airbag system. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. When supplied with the proper electrical signal, the inflator or inflators discharge the gas directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE DRIVER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 17236.89 kPa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. CAUTION: Deployed Front Air Bags may or may not have live pyrotechnic material within the air bag inflator. Do not dispose of Driver and Passenger Airbags unless you are sure of complete deployment. Please refer to the Hazardous Substance Control System for Proper Disposal. Dispose of deployed air bags in a manner consistent with state, provincial, local, and federal regulations. Use the following table to identify the status of the Airbag Squib. AIRBAG SQUIB STATUS 1. Using a DRBIII(R) read Airbag DTC's If the following active codes are present: If neither of the following codes is an active code: ACTIVE DTC SQUIB STATUS Driver squib 1 open Driver Squib 2 open Status of Airbag is Unknown. CLOCKSPRING The clockspring is mounted on the steering column under the steering wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wiring and the driver airbag, the horn, and the vehicle speed control switches if equipped. The clockspring Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 423 must be properly centered when it is reinstalled on the steering column following any service procedure, or it could be damaged. The clockspring cannot be repaired and it must be replaced. PASSENGER AIRBAG The front passenger airbag is equipped with dual stage squib inflators. When supplied with the proper electrical signal the inflator or inflators discharge the gas directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS INERT GAS PRESSURIZED TO 17236.89 kPa (2500 PSI). DO NOT ATTEMPT TO IS MANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR.DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. AIRBAG SQUIB STATUS 1. Using a DRBIII(R) read Airbag DTC's If the following active codes are present: If neither of the following codes is an active code: ACTIVE DTC SQUIB STATUS Passenger squib 1 open Passenger squib 2 open Status of Airbag is Unknown. CAUTION: Deployed Front Air Bags may or may not have live pyrotechnic material within the air bag inflator. Do not dispose of Driver and Passenger Airbags unless you are sure of complete deployment. Please refer to the Hazardous Substance Control System for Proper Disposal. Dispose of deployed air bags in a manner consistent with state, provincial, local, and federal regulations. Use the following table to identify the status of the Airbag Squib. SEAT BELT TENSIONER (SBT) The driver and passenger seat belt (buckle) tensioners are mounted to the inboard side of the front seats. The seat belt buckle and seat belt switch are connected directly to the seat belt tensioner cable. At the onset of an impact event the ORC uses the seat belt tensioner to rapidly retract the seat belt buckles. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. The seat belt tensioner cannot be repaired, if damaged or defective it must be replaced. The ORC continuously monitors the resistance of the seat belt tensioner circuits for open and shorted conditions. SEAT BELT SWITCHES (SBS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 424 The hall-effect driver and passenger seat belt switches provide the seat belt status, buckled or unbuckled, via hardwired inputs to the ORC. If the seat belt switch is damaged or defective the seat belt tensioner must be replaced. The ORC continuously monitors the seat belt switch circuits for open and shorted conditions. DRIVER KNEE BLOCKER AIRBAG The most visible part of the Driver Knee Blocker Airbag is the knee blocker trim cover. The knee blocker trim cover and airbag are mounted directly to the instrument panel structure below the steering column. When supplied with the proper electrical signal, the inflator discharges the gas directly into the airbag. The airbag cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: - DO NOT ATTEMPT TO MODIFY ANY PART OF YOUR ADVANCED AIRBAG SYSTEM. THE AIRBAG MAY INFLATE ACCIDENTALLY OR MAY NOT FUNCTION PROPERLY IF MODIFICATIONS ARE MADE. TAKE YOUR VEHICLE TO AN AUTHORIZED DEALER FOR ANY ADVANCED AIRBAG SYSTEM SERVICE. IF YOU'RE SEAT INCLUDING YOUR TRIM COVER AND CUSHION NEEDS TO BE SERVICED IN ANY WAY (INCLUDING REMOVAL OR LOOSENING/TIGHTENING OF EAT ATTACHMENT BOLTS), TAKE THE VEHICLE TO YOUR AUTHORIZED DEALER. ONLY MANUFACTURER APPROVED SEAT ACCESSORIES MAY BE USED. CONTACT YOUR AUTHORIZED DEALER IF IT IS NECESSARY TO MODIFY AN ADVANCED AIRBAG SYSTEM FOR PERSONS WITH DISABILITIES. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. FRONT AND SIDE IMPACT SENSOR The front and side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, and combined with the ORC Accelerometer Sensor provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller. The ORC microprocessor continuously monitors all of the front and side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a system fault, it sets a Diagnostic Trouble Code and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor signal and ground circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor signal circuit. If the sensor is dropped it must be replaced. CAUTION: Do not remove or install the impact sensors while the sensor is connected to the vehicle wiring. OCCUPANT CLASSIFICATION SYSTEM A non-calibrated Occupant Classification Module (OCM) is the only component of the Occupant Classification System (OCS) that is available for separate service replacement, as outlined in the procedures that follow. The OCS components of the passenger side front seat cushion including the cushion frame, springs, pad, seat weight bladder and pressure sensor, seat cushion foam and the OCM are a factory-calibrated and assembled unit. Once this unit is connected to a vehicle electrically, the calibration settings are uploaded from the OCM and stored in the memory of the Airbag Control Module (ORC). If only the OCM is subsequently replaced, the new, non-calibrated OCM learns the proper calibration settings from the ORC after it is connected to the vehicle electrically. If any of the remaining OCS components of the passenger side, front seat cushion require replacement, they are serviced only as a factory calibrated, assembled, and tamper-evident service replacement package. This package includes the assembled frame, springs, pad, seat weight bladder and pressure sensor, foam, wiring and a calibrated OCM. When installing this package, always replace all of the existing components with the new components as a unit. Do not attempt to separate or disconnect any of the new OCS components contained in the service replacement package from each other, and do not attempt to reuse any of the replaced components in this or any other vehicle. Once any of the original factory-installed components except the OCM have been replaced with the service replacement package components, the OCM can only be serviced by replacing the entire passenger side front seat cushion unit with another complete service replacement package. CAUTION: On vehicles equipped with the Occupant Classification System (OCS), never replace both the Airbag Control Module (ORC) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one. Then perform the supplemental restraint verification test before replacing the other. Both the ORC and the OCM store OCS calibration data, which they transfer to one another when one of them is replaced. If both are replaced at the same time, an irreversible fault will be set in both modules. The OCM is subsystem of the Airbag Control Module (ORC). Therefore the OCM bus message updates the ORC with the front passenger seat information via PCI Bus message. The ORC then controls the Passenger Off indicator and the Airbag Warning Indicator to provide system onboard diagnostic feedback. All OCS wiring repairs are prohibited; when wiring problems are diagnosed a Bladder Repair Kit is the only approved repair. Part 2 of 2 PASSENGER AIRBAG OFF INDICATOR Vehicles equipped with the Occupant Classification System (OCS) include a passenger airbag off indicator located in the Switch Bank in the center of the instrument panel. Vehicles without OCS have a blank lens installed in the instrument panel. At ignition on, for a system test, the ORC low side driver grounds a yellow Light Emitting Diode (LED) circuit causing the PASS AIRBAG OFF Indicator text and icon to be illuminated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 425 SEAT WEIGHT SENSOR Vehicles equipped with the Occupant Classification System (OCS) have a seat weight bladder and pressure sensor unit that is integral to the passenger front seat cushion. The pressure sensor receives a nominal five volts and a ground through dedicated hardwired circuits from the OCM. The OCM then monitors the pressure sensor output voltage. SEAT BELT TENSION SENSOR - BTS The Belt Tension Sensor (BTS) is designed to measure belt tension as an input to a passenger Occupant Classification System (OCS). It is used to detect high cinch loads associated with child seats and compensate for the seat cushion load to correctly classify occupant size. When a load is applied to the seat belt, the belt tension sensor measures the load. As the load changes, the circuitry of the belt tension sensor changes the output voltage of the sensor. The belt tension sensor receives a nominal five volts and a ground through dedicated hardwired circuits from the OCM. The OCM then monitors the belt tension sensor output voltage on a dedicated hardwired data communication circuit. If the vehicle has experienced any impact(s) resulting in deployment of a pyrotechnic device of any kind (airbag, seatbelt tensioner, side curtain, etc.) within the vehicle, the entire passenger seat belt retractor assembly, including the BTS, shall be replaced. Additionally, if the seat belt webbing has become cut, frayed, or worn; or if the stitching has become damaged in any way, the entire passenger seat belt retractor assembly, including the BTS, shall be replaced. The belt tension sensor cannot be repaired and, if faulty or damaged, the entire passenger side front seat belt and retractor unit must be replaced. The OCM Verification Test will also provide a BTS Verification procedure to verify the BTS function. This verification procedure requires the Miller Special Tool #8828. BLADDER REPAIR KIT There are only three replaceable components in the OCS, Occupant Classification Module, Bladder Repair Kit and the Passenger Airbag OFF Indicator. The Bladder repair kit contains the OCS bladder, wire harnesses, pressure sensor (Seat Weight Sensor), module, seat cushion and other related structural and sound deadening components. The module and sensor connector must have a Tamper Evident material installed on the service kit module and sensor connectors. This material provides visible evidence that the assembly has been separated after the calibration process was completed. Do not install a Bladder Repair Kit if it appears that any of the components have been disconnected. The OCM can be replaced if the Airbag Control Module has uploaded the seat calibration into memory in a previous ignition cycle and the new OCM has a blank VIN and no calibration data stored in memory. NOTE: - An OCM can only be replaced in a passenger front seat if the seat is equipped with the original OCS module, bladder, sensor and wiring. - Servicing the OCS may create additional active and stored trouble codes that must be resolved before the vehicle can be returned to the owner. The OCS Verification Test will also set active DTC's if the procedure is not completed successfully. The Miller Special Tool, MRL-9077 and the DRBIII are needed to successfully complete the system Verification Test. The DRBIII(R) may report the following NEW DRBIII(R) FEATURE ORC Menu The DRBIII(R) ORC System Test screen will display the following: 2VIN verification - Original VIN and Current VIN 2PCM Monitor - PCM Active On The Bus or PCM Not Active On The Bus The DRBIII(R) ORC Input/Outputs screen will display the following: - OCM Status: - Seat Class 0 (Empty) - Seat Cass 1 (Rear Facing Infant car Seat or RFIS) - Seat Class 2 (6 year old or Child) - Seat Class 3 (greater than or equal to 5th Percentile Female) - Seat Class 4 (less than 5th Percentile Female) - Seat Class 5 (Undetermined) The DRBIII(R) ORC Miscellaneous screen will display the following: - Configure Airbag On-Off Switch 1. No Airbag On-Off Switch 2. Pass OCM Only OCS Menu The DRBIII(R) OCM Input/Output screen will display the following: - OCS Status - 90, 919, 929, 939, 949, 959 The DRBIII(R) OCM Sensors screen will display the following: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 426 - Bladder Output - XXX A/D counts - Pas BTS Output - XXX A/D counts The DRBIII(R) OCM OCS Info Monitor screen will display the following: - Pass BTS -- Enabled or Disabled System Verification The DRBIII(R) OCM System Test screen will display the following: - PCM Monitor - PCM Active On The Bus or PCM Not Active On The Bus - Clear VIN Mismatch - Clear VIN Mismatch Complete - VIN Verification - Original VIN and Current VIN Clear VIN Mismatch - OCS Verification - OCS Verification Test process errors: Test In Progress Mode 33 Not Supported Subfunction not supported Test Busy - Repeat Test Conditions for Test Not Correct Routine Already Running Routine was Never Started Press any key to continue, then restart the verification test. Test failed conditions: Test Failed - Active DTC's Present Test Failed - Seat is Empty Test Failed - Seat Occupied Test Failed - Weight Above Threshold Test Failed - Weight Below Threshold Test Failed - Temperature Out of Range Test Failed - Seat Pressure Too High Test Failed - Seat Pressure Too Low Test Failed - Seat Pressure Not Stable Test Failed - Temperature Out of Range Test Failed - Seat Pressure Too Low Test Failed - Power Up Time Too Short Test Failed - Power Up Time Too Long Test Failed - K Empty Count is 0 Test Failed - No EOL Calibration Test Failed - K Allow is FF Allow the vehicle seat and interior temperature to stabilize, check voltage supplies and repair any other active DTC's before restarting the System Verification test. The OCS has been Verified or The OCS has NOT been Verified WARNING: - TO AVOID PERSONAL INJURY OR DEATH, TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING. - TO AVOID PERSONAL INJURY OR DEATH, TURN THE IGNITION ON, THEN RECONNECT THE BATTERY. - TO AVOID PERSONAL INJURY OR DEATH ON VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS), ONLY THE OCCUPANT CLASSIFICATION MODULE (OCM) AND THE PASSENGER SEAT BLADDER AND CUSHION SERVICE KIT ARE THE ONLY PARTS SERVICED. - IF THE OCCUPANT CLASSIFICATION MODULE IS DROPPED AT ANY TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. TO AVOID PERSONAL INJURY OR DEATH ON VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS), ONLY THE OCCUPANT CLASSIFICATION MODULE (OCM) AND THE SEAT CUSHION TRIM MAY BE SERVICED SEPARATELY. ALL OTHER COMPONENTS OF THE PASSENGER SIDE FRONT SEAT CUSHION ASSEMBLY MUST BE SERVICED ONLY AS A COMPLETE FACTORY-CALIBRATED, ASSEMBLED AND TAMPER-EVIDENT SERVICE REPLACEMENT PACKAGE. THIS PACKAGE INCLUDES THE FRAME, SPRINGS, PAD, BLADDER AND PRESSURE SENSOR, FOAM, WIRING AND A CALIBRATED OCM. WHEN INSTALLING THIS PACKAGE ALWAYS REPLACE ALL OF THE EXISTING COMPONENTS WITH THE NEW COMPONENTS AS A UNIT. DO NOT ATTEMPT TO SEPARATE OR DISCONNECT Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 427 ANY OF THE NEW OCS COMPONENTS IN THE SERVICE REPLACEMENT PACKAGE FROM EACH OTHER, AND DO NOT ATTEMPT TO REUSE ANY OF THE REPLACED COMPONENTS IN THIS OR ANY OTHER VEHICLE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN FAILURE OF THE PASSENGER AIRBAG TO DEPLOY WHEN REQUIRED, OR IN PASSENGER AIRBAG DEPLOYMENT WHEN NOT REQUIRED. SPECIAL TOOLS Some airbag diagnostic tests will require the use of special tools, airbag load tools, 8443 for testing squib circuits and the Occupant Classification Seat Weight Tool 9077. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of a Driver or Passenger Airbag, curtain airbag, clockspring, or seat belt tensioner (use a jumper if needed). Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective component has been removed from the system and should be replaced. If the DTC is still active, continue this process until all components in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed the squib wiring can be tested for open and shorted conditions. DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes with the DRBIII(R). This will direct you to the specific test(s) that must be performed. In certain test procedures diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The code becomes active as soon as the malfunction is detected or key-on, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the Occupant Restraint Controller checks that circuit or component. It is impossible to erase an active code. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. STORED CODES Airbag codes are automatically stored in the ORC's memory as soon as the malfunction is detected. A stored code indicates there was an active code present at some time. When a trouble code occurs, the Airbag Warning Indicator illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). Once the code is no longer active, the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected will be displayed. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. The ignition cycle counter will be reset and diagnostic trouble code will continue to be a stored code, If the malfunction reoccurs before the count reaches 100. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. Maintain a safe distance from all airbags while performing the following inspection. If no obvious problems are found, erase stored codes, and with the ignition on wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Audio System Some of the radios are on the PCI Bus system. The PCI Bus inputs into the radio are used for VF dimming, remote steering wheel controls and cabin EQ preference. PCI Bus outputs from the radio are used for the Name Brand Speaker (NBS) relay activation, as well as cabin EQ preference. The radios have the capability of containing multiple vehicle unique equalization curves (cabin EQ preferences) within the radio. These curves will reside in the radio's flash memory. The radio is capable of storing up to 20 unique equalization curves. The latent curves can be selected via the Front Control Module transmitting a PCI Bus message to the radio in response to a radio request for equalization message. Upon receipt of a valid equalization select message response, the radio will switch to output the corresponding equalization curve. All the radios are capable of displaying faults and allowing certain actuation tests through the use of the DRBIII(R). When attempting to perform PCI Bus diagnostics, the first step is to identify the radio in use in the vehicle. When trouble shooting output shorts or 'output' error messages, the following applies: On radios without an external amplifier, the term output refers to the path between the radio and the speaker. This type of circuit can be monitored all the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 428 way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio, or wiring could be at fault. On radios with an external amplifier, the term 'output' refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. NAVIGATION RADIO The optional navigation radio system receives GPS signals from up to eight satellites to display the position and direction of the vehicle. Map information is supplied through a DVD-ROM. An electronic gyrosensor and the vehicle's speed sensor enable the system to display the present vehicle position even in locations where GPS signals may be blocked. When a destination is selected, the navigation system uses information from the map to quickly calculate a route. As the vehicle is driven along the chosen route, the operator is guided with pictorial displays and voice prompts. For complete operating instructions, refer to the manual included with the vehicle. REMOTE RADIO CONTROLS These radios can be controlled via remote radio switches (optional). These switches are located on the back side of the steering wheel. They control mode, preset, seek up, seek down, volume up and volume down functions. These functions are inputs to the Body Control Module and can be read with the DRBIII(R) under 'body computer'. The switches are a multiplexed signal to the BCM. The radio control MUX circuit is a 5 volt line that is pulled to ground through different value resistors built into the switches. This causes a voltage drop to be seen by the BCM and it sends a specific message to the radio on the PCI Bus circuit. The radio then responses to the message. This circuit is fairly simple to troubleshoot. The circuit must be complete from the switches in the steering wheel to the BCM. The ground must be complete so that the switches can cause the voltage drop for the BCM to see. The circuit passes through the clockspring so continuity through this devise must be verified. CD CHANGER The new in-dash CD Changer is designed to fit into the existing cubby bin in the center stack. This new cartridge-less CD Changer is controlled by your radio, and allows you to individually load up to four discs at a time. However, due to its compact design, the CD Changer can only carry out one operation at a time. For example, you can not load a new disc while playing another at the same time. Each operation happens sequentially. The radio unit installed with your system provides control over all features of the CD Changer with the exception of the CD load and eject functions, which are controlled by buttons located on the front of the CD Changer. The radio also supplies the power, ground, PCI Bus, left and right speaker output through a single DIN cable. All features you would expect, such as Disc Up/Down, Track Up/ Down, Random and Scan are controlled by the radio, which also displays all relevant CD Changer information on the radio display. The CD Changer contains a Load/Eject button and an indicator light for each of the four disc positions. The individual light indicates whether a CD is currently loaded in that particular chamber of the CD Changer. Pressing the individual Load/Eject button for a particular chamber will eject a disc currently present in that chamber. If the chamber is currently empty, actuating the Load/Eject button will position that chamber to receive and load a new disc in that chamber. DVD/CD CHANGER The DVD/CD Changer (if equipped) is located in the instrument panel below the radio. The DVD/CD Changer can hold one DVD at a time. Three RCA jacks on the front of the unit will allow the use of MP3 players, video systems or camcorders. Body Control Module The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (PCI). This network consists of the powertrain control module (PCM), the engine control module (ECM) diesel, the mechanical instrument cluster (MIC), the front control module (FCM), the occupant restraint controller (ORC), the occupant classification module (OCM), the overhead console, the ABS module, the hands free module (HFM), the park assist module, the HVAC control module (ATC & MTC), the power sliding door (Left & Right) modules (PSD), the power liftgate module (PLG), the Audio system (which includes the Radio, DVD, CD Changer and Amplifier), the memory seat/mirror/ adjustable pedals module (MSMAPM), the RKE/ Thatcham alarm module (export), the transmission control module (Diesel only) and the sentry key remote entry module (SKREEM). The BCM is operational when battery power is supplied to the module. The body control module provides the following features: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 429 - Power Door Locks - Automatic Door Lock - Door Lock Inhibit - Central Locking (with VTSS Only) - Battery Protection - The BCM will automatically turn off all exterior lamps after 3 minutes and all interior lamps after 15 minutes after the ignition is turned off, if they are not turned off by the driver. - Chime Driver - Compass/Minitrip Support - Interior Lighting (Courtesy/Reading Lamps) - BCM Diagnostic Reporting - Electronic Liftgate Release (with Power Door Locks) - Exterior Lighting - Headlamp Time Delay (with/without Auto headlamps) - Automatic Headlamps (with electrochromatic mirror) - Illuminated Entry - Fade to Off This feature dims the interior lighting (courtesy lamps) gradually if the BCM does not receive any new inputs that would cause the interior lamps to remain on. - PWM Instrument Panel Dimming - Door Lock Inhibit This feature disables the door lock functions if the key is in the ignition and either front door is ajar. Pressing the RKE lock/unlock button under these conditions, result in normal lock/unlock activation. - Power Sliding Door Switch Inputs The BCM has 4 switch inputs for the power sliding door feature: Located in the overhead console are the Left and Right side sliding door switches to activate either or both sliding doors under the proper conditions. Also there are B-Pillar switches located on the Left and Right B-pillar posts. - Power Liftgate Switch Input The BCM has 1 Liftgate switch input located in the overhead console - Power Lockout Switch Input The BCM has 1 Lockout switch that when enabled will disable the B-Pillar sliding door switches from activating either sliding door when depressed. When replacing a body control module there are 2 modules available, a Base and a Midline. The Midline controller is used on vehicles that have Power Door Locks. If a vehicle is equipped with the Vehicle Theft Security System, the midline controller becomes a premium when the theft feature is enabled. NOTE: Do not swap the body control module between vehicles or body control modules off the shelf. Engineering does not recommend that service, dealers or the plant swap Body Control Modules (BCM) between vehicles or off the shelf. The BCM has internal diagnostic capability that assists in diagnosing the system. When an 'open' or a 'Short' circuit exists, the diagnostic tool can be used to read the BCM codes. The codes are very descriptive in identifying the appropriate feature that has faulted. The BCM also learns what features are on the vehicle and if modules are swapped the BCM could set false DTC's based on what it learned. Chime Warning System The BCM monitors the door/liftgate ajar switches, multifunction switches, headlight switch, ignition switch, PCI bus, and the diagnostic tool to perform various chime operations. The BCM uses a low-side driver to control the chime located in the cluster. The chime system provides the Driver with warning chimes for: - Seat belt - Exterior lights on - Key-in Ignition - Key-in Accessory - Engine temperature critical - Low washer fluid - Turn signals on - Dome light on - Low oil pressure - Any warning lamp announcement - High-speed warning Gulf Coast Countries (GCC) only The output sound intensity of the chime is approximately 72 decibels. CHIME PRIORITY Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 430 The following list indicates the priority of the chime when more than one chime is active at the same time: - Seat belt warning - High-speed warning Gulf Coast Countries (GCC) only - Turn signal on - Chime request - Warning lamp announcement The cluster is responsible to set priority on all warning lamp announcement chimes. CHIME ON CONDITIONS The following is a list of the chime warnings and when they will sound. Driver's Seatbelt Unbuckled: Sounds for approximately 6 ± 2 seconds when the ignition is turned on driver's seat belt is not buckled, as a reminder to the driver to buckle the seat belt. Exterior Lights On:Ignition is in the lock position, the driver door is ajar, and the headlight switch is left in any position, other than auto or off.The chime will sound as a warning to the driver until one of the above conditions is removed or until the battery protection time of 3 minutes has expired. Key-In Ignition: Ignition is in the lock position, driver door is ajar and the key is in the ignition. The chime will sound until one of the above conditions is removed or until the battery protection time of 15 minutes has expired. Turn Signal On: When the BCM detects a turn signal input continuously for 1.0 mile/0.6 km and the vehicle speed is greater than 15 mph/24 kph, the chime will sound until the specific turn signal is cancelled. Dome Lights On: Ignition is in the lock position, driver door ajar, and the dome light switch is left in the on position. The chime will sound until one of the above conditions is removed or until the battery protection time of 15 minutes has expired. Low Oil Pressure: The chime will sound when the engine is operating and the oil pressure drops below 4 psi/27.5 kPa. Engine Temperature Critical: The chime will sound when the engine is operating and the coolant temperature exceeds 252° F/122° C or 234° C/112° C(diesel). The chime is continuous at 257° F/ 125° C and will chime for 4 minutes and stop if the temperature drops below 255° F/123° C. Low Washer The chime will sound when the Fluid washer fluid drops below a specific level. Warning Lamp Announcement: A chime will sound to alert the driver to scan the instrument panel and overhead console to see which warning lamp is illuminated. The door/liftgate ajar warning lamp will appear without a chime if the vehicle is running and a door or the liftgate is opened. A chime will sound if the door or liftgate is still open and the vehicle speed is greater than 4 mph/6 kph. High-speed warning Gulf Coast Countries (GCC) only The chime will sound, acting as a warning to the driver that the vehicle speed has exceed 75 mph ± 2/120 kph ± 3. WARNING LAMP ANNOUNCEMENT Low Fuel Lamp: The cluster will request a single chime after the indicator is illuminated. Volt Lamp: The cluster will request a single chime after the indicator is illuminated. Oil Pressure Lamp: The cluster will request a single chime after illuminating the indicator above 450 rpm vehicle operation. Liftgate Ajar Lamp: The BCM determines when to chime for liftgate ajar. Fasten Seat Belt Lamp: The MIC will request a single chime from the BCM when the ignition is turned to the unlock/ run/start positions if the driver seat belt is not buckled and 2 seconds after seatbelt warning chime ends. Check Engine Lamp: The cluster will request a single chime after the indicator is illuminated. Low Washer Fluid Lamp: The cluster will request a single chime after the indicator is illuminated. Engine Temperature Lamp: The cluster will request a single chime when the indicator is first illuminated at 252° F/122° C. OTHER CHIME ON CONDITIONS Programming of an Additional Key Fob: A single cluster chime will sound, which signals that the program mode has been initiated. Programming for Rolling Door Locks: When the programming has been completed, a single tone from the chime system, will occur. Communication Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 431 The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25 and is white with a violet tracer. Additional tracer colors may be added to the violet in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on the RS/RG: - Body Control Module - Front Control Module - Occupant Restraint Controller - Occupant Classification Module - Controller Antilock Brake (MK20E) - Antilock Brake Module (MK25E) - Powertrain Control Module (Gas) - Transmission Control Module (Diesel Auto Only) - Engine Control Module (Diesel) - Radio - Amplifier - CD Changer - DVD/CD Changer - Hands Free Module - Automatic Temperature Control Module - A/C Heater Control Module (MTC) - Sentry Key Remote Entry Module (SKREEM) - Memory Seat/Mirror/Adjustable Pedals Module (MSMAPM) - Overhead Console - Mechanical Instrument Cluster - Left Sliding Door Control Module - Right Sliding Door Control Module - Thatcham Alarm Module (Export) - Power Liftgate Module - Park Assist Module Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRBIII(R) lab scope. The 12 v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open PCI circuit at the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: - All gauges on the MIC stay at zero - All telltales on MIC illuminate - MIC backlighting at full intensity - Dashed lines in the overhead console ambient temperature display - No response received from any module on the PCI bus (except the PCM/ECM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRBIII(R). Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected,suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRBIII(R) If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRBIII(R) may display BUS ± SIGNAL OPEN or NO RESPONSE to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRBIII(R) and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. NOTE: For 2005 model year, some vehicles will integrate the Transmission Control Module and Powertrain Control Module into a single control module. This new module is the Next Generation Controller for DaimlerChrysler and will be referred to as the Powertrain Control Module (PCM). The Transmission Control Module is part of the Powertrain Control Module. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 432 Diagnostic procedures and DTC numbers are some of the changes you will see which reflect the new combined module technology. The PCM will have four color coded connectors C1 through C4, (C1-BLK, C2-ORANGE, C3-WHITE, C4-GREEN), each PCM connector will have 38 pins each. Two new tools are used for probing and repairing the New PCM connectors. A New tool to release the pins from the PCM connectors Miller #3638 is introduced, you must use the Miller tool #3638 to release the connector pins or harness and connector damage will occur. Also a New tool for probing connectors Miller #8815 is introduced, you must use the Miller tool #8815 to probe the PCM pins or harness and connector damage will occur. There is also a new Verification test and module replacement procedure for the PCM. Door Ajar System The door ajar and liftgate ajar states are used as inputs for the Body Control Module (BCM). The BCM uses these inputs to determine exactly what position the doors and liftgate are in. The DRBIII(R) will display the state of the door ajar and the liftgate ajar switches in Inputs/Outputs. It's important to note, that when any door, or the liftgate is closed, the switch state on the DRBIII(R) will show OPEN. When any door, or the liftgate is open the switch state on the DRBIII(R) will show CLOSED. During diagnosis, if a door or the liftgate is closed and the DRBIII(R) displays the switch state as CLOSED, it indicates a shorted ajar circuit. If the door or the liftgate is open and the DRBIII(R) displays the switch state as OPEN, it indicates an open ajar circuit. Exterior Lighting System HEADLAMP POWER The Headlamp Switch is a direct input to the BCM. The BCM sends a BUS message to the FCM informing it of a headlamp switch status change. The FCM then turns on power to the headlamps through four fuseless circuits. These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied to each filament in a separate circuit. For vehicles equipped with daytime running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination. HEADLAMP SWITCH The Headlamp Switch uses a multiplexed (MUX) circuit to the Body Control Module (BCM). The Headlamp Switch controls the Fog lamp relay, Park lamps and the Low and High headlamps. The BCM then sends a signal through the PCI Bus line to the FCM as to what state the switch has selected. The FCM energizes the high side output drivers to turn ON the desired lamps. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 433 PARK LAMP RELAY The Park Lamp Switch is a direct input to the BCM. The BCM sends a BUS message to the FCM informing it to turn on the park lamp relay. The park lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. FOG LAMP RELAY The Fog Lamp switch is a direct input to the BCM. The BCM sends a BUS message to the FCM informing it to turn on the fog lamp relay. The fog lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Fog lamp functionality is not equipped on all vehicles. The FCM learns that the vehicle is equipped with fog lamps by reading the BCM BUS message. FOG LAMPS The BCM controls the operation of the fog lamp relay that turns the fog lamps ON and OFF. The Fog lamps can only be ON when the park and low beams are ON. If the high beams are switched ON then the Fog lamps will be automatically turned OFF. EXTERIOR LIGHTING BATTERY SAVER The BCM monitors the status of, and controls, the Park Lamps, Headlamps and Fog Lamp relays. If any exterior lamps are left ON after the ignition is turned OFF, the BCM will turn them OFF after 3 minutes. AUTO HEADLAMPS This feature is available on vehicles equipped with both the Electrocromatic Mirror (ECM) and the Compass/Mini-Trip Computer (CMTC). When the BCM detects a day/night signal from the CMTC, an ECM is present and Auto Headlamp mode is selected. Front Control Module The Front Control Module (FCM) is an electrical control and interface center located in the engine compartment. When it is mated to the Power Distribution Center (PDC), it is referred to as the Integrated Power Module (IPM). The IPM, with its fuses and relays provides power and signal distribution throughout most of the vehicle. The FCM receives both hard wire and digital electronic inputs from the vehicle electrical system through the PDC. Based on these inputs and the ignition switch position, it provides direct power feeds and relay control to some of the vehicles most critical electrical systems. The Front Control Module provides the following features: Controlled power feeds: - Front airbag system - Headlamp power - EATX module power (4 speed only) - Front washer motor - Rear washer motor - Cabin Heater - Brake shift interlock system Relay controls: - Fog lamp relay (when equipped) - Park lamp relay - Front wiper on relay - Front wiper high/low relay - Accessory relay - Horn relay - Front & rear blower relay - Name brand speakers (NBS) relay - Adjustable pedals relay (non-memory) - Electronic back light (EBL) run only relay Electrical inputs: - Headlamp battery supplies 1 & 2 - Module battery supply - Power ground - Ignition switch RUN or START position status - Ignition switch START only status - PCI Bus - Stop lamp switch - Horn switch - Back-up switch - Wiper park switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 434 - Washer fluid level switch - Brake fluid level switch - Ambient temperature sensor - Right park lamp outage - Left park lamp outage - Battery IOD - Battery (+) connection detection - Flash reprogramming voltage CONTROLLED POWER FEEDS Front airbag system The FCM provides power to the Occupant Restraint Control (ORC) system through two fuseless circuits (ORC RUN/START, and ORC RUN only). These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied while the ignition switch is in the RUN and START positions on pin 48 of the FCM connector, and in the RUN only position on pin 29. Headlamp power The headlamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a headlamp switch status change. The FCM then turns on power to the headlamps through four fuseless circuits. These circuits are electronically controlled and continuously monitored for malfunctions.Power is supplied to each filament in a separate circuit. For vehicles equipped with Daytime Running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination. EATX power The electronic automatic 4 speed transmission module is powered when the ignition switch is in the UNLOCK, RUN or START positions. This circuit is electronically controlled and continuously monitored for malfunctions. Power is supplied through pin 27 of the FCM connector. Front washer motor The front washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The front washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition, the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Rear washer motor The rear washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The rear washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition,the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Cabin Heater When the ignition is in Run, the FCM monitors the PCI bus for the Cabin Heater Activation request. The Automatic or Manual Temperature Control initiates this request only when all conditions for the Cabin Heater activation are favorable. The request carries the status bit that the FCM requires to activate its Cabin Heater Assist Control output. This output is a low side driver (coming from FCM pin 15) which supplies a ground signal to the Cabin Heater (pin 5). When the Cabin Heater receives this ground signal input, it interprets this as an activation signal. The FCM low side driver is also capable of diagnostic sensing. The driver will sense an open circuit when the driver is off, and will sense a short to voltage when the driver is on. The FCM will set DTC's for both of these types of faults. For additional information, refer to Cabin Heater under General Information and Diagnostic Procedures in the manual. Brake shift interlock system The brake shift interlock solenoid receives power from both high side and low side controls inside the FCM. The high side control is on the same circuit as the EATX module power, and the low side control comes through pin 47 of the FCM connector. The solenoid is controlled by the low side driver when the brake pedal is pressed. Both circuits are continuously monitored for malfunctions. RELAY CONTROLS Fog lamp relay The fog lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the fog lamp relay. The fog lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Fog lamp functionality is not equipped on all vehicles. The FCM learns that the vehicle is equipped with fog lamps by reading the BCM PCI Bus message. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 435 Park lamp relay The park lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the park lamp relay. The park lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper on relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper on relay. The front wiper on relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper high/low relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper high/ low relay. The relay switches power between the low speed and high speed windings of the wiper motor. The front wiper high/low relay is powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Accessory relay The accessory relay works in conjunction with the FCM's power accessory delay feature to control the operation of the radio, power windows, washer motors,wiper motors and power outlet. The accessory relay is turned on through low side control on pin 35 of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Depending on the ignition switch position, the accessory relay will remain on or will time-out and turn off. The accessory relay remains on in the RUN and ACCY positions of the ignition switch. In the UNLK and OFF positions, the relay will remain energized for 45 seconds then turn off. During this time-out period, if the driver or passenger doors are opened, the relay will turn off immediately. While the ignition switch is in the START position, the relay will also drop-out, then resume operation. Accessory relay operation is most noticeable by observing the operation of the radio or blower functions. Horn relay The horn relay operates through a direct wire input to the FCM from the horn switch (FCM pin 17) , or a PCI Bus message from the BCM. The relay responds to the horn switch, remote door lock and VTA alarm functions. The horn relay is powered through low side control on pin 10 of the FCM. Under normal operating conditions, if the horn is pressed for longer than 30 seconds, the FCM will automatically deactivate the horn to prevent damage to it. The FCM will re-activate control of the relay after a 25 second cool-down period. This circuit is electronically controlled and continuously monitored for malfunctions. Front and rear blower relay RS with MTC Upon ignition on, the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus.The front blower relay and the rear blower relay, if equipped, are then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. RG with MTC Upon power up (Power switch on), the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus. The front blower relay is then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. Name Brand Speakers (NBS) relay The NBS relay operates through the vehicle bus interface between the radio and the FCM. When the radio is turned on, the radio sends a PCI Bus message to the FCM. The NBS relay is then powered on through low side control on pin 11 of the FCM. The relay supplies power to the amplified speaker, and ground is supplied through the radio. This circuit is electronically controlled and continuously monitored for malfunctions. Electronic Back Light (EBL) relay The rear defrost switch is part of the Automatic Temperature Control or A/C-Heater Control Module (Manual Temp). When the ignition switch is in the RUN position and the rear defrost switch is turned on, the ATC or A/C-Heater Control Module sends a PCI Bus message to the FCM. The EBL run only relay is then powered through low side control on pin 31 of the FCM. The relay provides the high side to the rear window defrost grid, and ground is attached to the vehicle body. The FCM will only allow the rear defrost to operate in the RUN position. This circuit is electronically controlled and continuously monitored for malfunctions. Adjustable Pedals Relay (Non-Memory) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 436 The Adjustable Pedals Relay is only on nonmemory Adjustable Pedals System equipped vehicles. The relay is supplied battery voltage from the IPM and is electronically controlled with a low side driver within the FCM. The relay is energized when the transmission is in reverse and when cruise control operation is engaged. This action disables the Adjustable Pedals System from movement. This circuit is continuously monitored for proper function. ELECTRICAL INPUTS Headlamp battery supplies 1 & 2 - 12 volt input on pins 1 and 2. Battery supply voltage for switching headlamp circuits only. Module battery supply - 12 volt input on pin 9. Battery supply voltage for all other FCM operations. Power ground - Ground source on pin 8 for all FCM operations. Ignition switch RUN or START position status - 12 volt input on pin 37. Allows the FCM to determine the ignition switch status for related FCM operations. PCI Bus - Approximately 7.5 volt input on pin 22. Allows the FCM to communicate with other modules on the vehicle bus. Stop lamp Switch status - 12 volt input on pin 44. Provides for brake shift interlock function. Horn Switch - Ground input on pin 17. Primary means for engaging the horn. Back-up switch - Ground input on pin 39. Input is converted to a PCI Bus status message for use by other modules. Wiper park switch - Ground input on pin 16. Used to determine park placement of wipers. Also used as feedback to FCM to determine correct operating mode of wipers. Washer fluid level switch - Ground input to pull-up on pin 18. Ground is switched into the circuit when washer bottle fluid level is low. Brake fluid level switch - Ground input to pull-up on pin 36. Ground is switched into the circuit when brake fluid level is low. Ambient temperature sensor - Resistive input to pull-up on pin 25. Corresponding voltage level is converted to a PCI Bus message for use by other modules on the bus. Right park lamp outage - 12 volt input on pin 21. Used to determine if right park lamp circuit is operating properly. Left park lamp outage - 12 volt input on pin 41. Used to determine if left park lamp circuit is operating properly. Battery IOD - 12 volt input on pin 20. The FCM enters a low power consumption mode when the ignition is turned OFF. This low current draw battery supply keeps the microprocessor functioning in the low power mode. Battery (+) connection detection - 12 volt input on pin 38. The battery connection on the PDC incorporates the use of an internal switch to determine if the connector is properly mated and the Connector Positive Assurance (CPA) is engaged. If the CPA is not properly engaged, a voltage on pin 38 will be interpreted as an unseated connector and a fault will set. Flash programming voltage - 20 volt input on pin 42. When a DRBIII(R) is connected and the proper flash reprogramming sequence is selected, the 20 volt signal will be applied through pin 42. Heating and A/C System AUTOMATIC TEMPERATURE CONTROL (ATC) MODULE USAGE CAUTION: Do not swap ATC Modules from vehicle to vehicle. Software versions differ between models and between model years. Installing a ATC Module with software that is incompatible for a given vehicle can result in either improper or failed HVAC system operation. SYSTEM AVAILABILITY - The ATC system is a Three-Zone Air Conditioning System. SYSTEM CONTROLS The ATC Module: - is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - provides an A/C request over the PCI Bus to the Powertrain Control Module (PCM) when compressor operation is desired. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 437 - for exports with diesel engines, provides a Cabin Heater activation request over the PCI Bus to the Front Control Module (FCM) when conditions are favorable for Cabin Heater operation. - uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - uses input from infrared (I/R) sensors, which measure surface temperature, to maintain occupant comfort levels. The I/R sensors are mounted in the instrument panel center bezel. - can be operated in a manual mode. - provides a blower relay on request over the PCI Bus to the Front Control Module (FCM) when blower operation is desired. - controls front blower operating speed, providing 10 speeds in manual mode and infinite speeds in automatic mode. - provides a cold engine blower lockout function. A Blower Speed Clamping feature minimizes occupant discomfort by controlling the amount of warm air coming out of the HVAC system should the Powertrain Control Module (PCM) disable A/C Compressor operation while the Automatic Temperature Control (ATC) is set in an automatic mode. The PCM disables the A/C compressor if the A/C pressure is too low, if the A/C pressure is too high, if engine overheating is immanent, or if an engine overheating condition exists. The ATC clamps the blower speed if the outside air temperature is greater than 50° F (10° C) and the PCM has disabled the A/C compressor. This means that the ATC will not adjust blower speed automatically when the clamping feature is enabled, e.g. if the clamping feature is enabled while in Auto Lo the blower will continue to run in low speed; if the clamping feature is enabled while in Auto Lo and the operator selects Auto Hi the blower will continue to run in low speed; if the clamping feature is enabled while in Auto Hi the blower will continue to run at the highest speed. In any case the operator can manually change the blower speed as desired. When diagnosing blower related symptoms verify that none of the above conditions for disabling the A/C compressor exist before diagnosing the blower circuits and components. - controls rear blower operating speed, providing 10 speeds in manual mode and infinite speeds in automatic mode. The separate front and rear Blower Motor Controllers operate as follows: When blower operation is desired, the Blower Motor Controller provides a 10.0 volt signal to the ATC Module over a control circuit. The ATC Module provides a variable duty cycle ground to the 10.0 volt signal based on input from the blower switch. When the blower switch is set to LO speed, the ATC Module provides a short duty cycle (less time grounding the signal voltage). As higher blower speeds are requested, the ATC Module increases the duty cycle (more time grounding the signal voltage). When the blower switch reaches HI speed, the duty cycle increases to where the signal pattern is almost a flat line (with brief voltage spikes). - controls the front and rear electric door actuators operation. A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The ATC Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the ATC Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. - activates and deactivates the Rear ATC Switch. The Rear ATC Switch (Three-Zone Only): - provides desired rear blower speed input to the ATC Module. - provides desired rear blend and mode door position input to the ATC Module. The Dual-Zone ATC system uses: - two front, two-wire electric blend door actuators. - one front, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. The Three-Zone ATC system uses: - two front, two-wire electric blend door actuators. - one front, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. - one rear, two-wire electric blend door actuator. - one rear, two-wire electric mode door actuator. System Relays: - The Integrated Power Module (IPM) houses and provides power to the A/C Clutch Relay, Front Blower Motor Relay, and Rear Blower Motor Relay. SYSTEM REVISIONS The 2005 ATC system remains mostly carryover from 2004. Revisions to the 2005 ATC system include: - all new version 0012 software. SYSTEM DIAGNOSTICS Fault detection is through active and stored Diagnostic Trouble Codes (DTC's) - DTC's are displayed the DRBIII(R). - Active DTC's are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTC's are those which occurred in the system since the ATC Module received the last "clear diagnostic info" message. The AC Cooldown Test: - is actuated with the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 438 - checks A/C system performance based on evaporator temperature sensor input. WARNING: DO NOT OPERATE THE DCHA IN AN ENCLOSED AREA SUCH AS A GARAGE THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS VENT THE DCHA's EXHAUST WHEN OPERATING THE DCHA. REFER TO VENTING THE DCHA's EXHAUST UNDER CABIN HEATER IN THE GENERAL INFORMATION PORTION OF THIS SECTION FOR PROPER EXHAUST VENTING INSTRUCTIONS. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. CAUTION: Do not activate the A/C Cooldown Test with the engine off. Failure to follow these instructions can result in internal damage to the DCHA Heater Module. - The FCM monitors the PCI bus for the Cabin Heater Activation request. The request carries the status bit that the FCM requires to activate it's Cabin Heater Assist Control output. This output is a low side driver (coming from FCM pin 15) which supplies a ground signal to the Cabin Heater (pin 5). When the Cabin Heater receives this ground signal input, it interprets this as an activation signal. - The FCM low side driver is also capable of diagnostic sensing. The driver will sense an open circuit when the driver is off, and will sense a short to voltage when the driver is on. The FCM will set DTC's for both of these types of faults. For additional information, refer to Cabin Heater under General Information and Diagnostic Procedures. - will not run the air conditioning portion of this test if ambient temperature is below 12° C (53° F). The forced Cabin Heater activation will occur even if the air conditioning portion of this test fails to initiate because AC Cooldown test criteria was not met. When activated, the DCHA will operate for approximately seven minutes. Three minutes to run and four minutes to purge. - will pass the air conditioning portion of this test if the evaporator temperature drops 6.7° C (20° F) within two minutes of starting this test. - messages (air conditioning related only) display on the DRBIII(R) after running this test. These messages will clear after paging back out of this test. Therefore, it is important to note all of the AC Cooldown test messages before doing so. - All Cabin Heater-related DTC's display under Cabin Heater, Read DTC's. - will cause the DELAY and Snowflake VF segments on the ATC to flash for 162 seconds (RG with DCHA only). If the air conditioning portion of this test fails, the DELAY and Snowflake VF segments will continue to flash until the vehicle is driven more than three miles. MANUAL TEMPERATURE CONTROL (MTC) Vehicle Compatibility For MTC Modules MODULE USAGE SYSTEM AVAILABILITY - Three different types of systems are currently available for these vehicles. Single-Zone Air Conditioning System - Dual-Zone Air Conditioning System - Three-Zone Air Conditioning System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 439 SYSTEM CONTROLS The A/C-Heater Control Module: - is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - provides an A/C request to the Powertrain Control Module (PCM) over the PCI Bus when compressor operation is desired. - uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - for exports with diesel engines, provides a Cabin Heater activation request to the Front Control Module (FCM) over the PCI Bus when conditions are favorable for Cabin Heater operation. - for RS vehicles, provides a blower relay on request to the FCM over the PCI Bus upon ignition on. - for RG vehicles, provides a blower relay on request to the FCM over the PCI Bus when the Power switch on the A/C-Heater Control Module is turned on. - controls front blower operating speed. For RS vehicles, the four speed settings are Low, M1, M2, and High. For RG vehicles the five speed settings are Low, M1, M2, M3, and High. - for RS vehicles uses the blower switch to control system on/off and blower speed. - for RS vehicles uses the rear wiper/washer switch to control rear wiper/washer operation. - for RS vehicles, provides a rear wiper on request to the Body Control Module (BCM) when rear wiper operation is desired. - for RS vehicles, provides a rear washer on request to the Body Control Module (BCM) when rear washer operation is desired. - controls EBL operation. - on three-zone systems, activates and deactivates the Rear A/C-Heater Control. - on three-zone systems, controls rear blower operating speed. The three speed settings are Low, Med, and High. - controls the front and the three-zone system rear electric door actuators operation. A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C - Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. On Three-Zone systems, the Rear A/C-Heater Control: - controls rear blower motor operating speed. The three blower speeds are Low, Med, and High. - provides desired rear blend and mode door position input to the A/C-Heater Control Module. The Single-Zone HVAC system uses: - one, two-wire electric blend door actuator. - one, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. The Dual-Zone HVAC system uses: - two, two-wire electric blend door actuators. - one, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. The Three-Zone HVAC system uses: - two front, two-wire electric blend door actuators. - one front, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. - one rear, two-wire electric blend door actuator. - one rear, two-wire electric mode door actuator. System Relays: - The Integrated Power Module (IPM) houses and provides power to the A/C Clutch Relay, Front Blower Motor Relay, and Rear Blower Motor Relay. SYSTEM REVISIONS The 2005 MTC system remains mostly carryover from 2004. Revisions to the 2005 MTC system include: SYSTEM DIAGNOSTICS Fault detection is through active and stored Diagnostic Trouble Codes (DTC's) - DTC's are displayed by the DRBIII(R). - Active DTC's are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTC's are those which occurred in the system since the A/C-Heater Control Module received the last "clear diagnostic info" message. The A/C Cooldown Test: - is actuated with the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 440 - checks A/C system performance based on evaporator temperature sensor input. - will not run if ambient temperature is below 12.7° C (55° F). - will pass if the evaporator temperature drops 6.7° C (20° F) within two minutes of starting the test. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - for RS vehicles will cause the Rear Wipe/Wash and A/C status indicators on the A/C-Heater Control Module to flash alternately while the test is running. - for RG vehicles will cause the PWR and A/C status indicators on the A/C - Heater Control Module to flash alternately while the test is running. The A/C status indicator will flash twice per second to indicate that the A/C Cooldown Test needs to be run. The A/C status indicator will stop flashing twice per second if either the A/C Cooldown Test returns passed, or if any button on the control is pressed, or if the ignition is cycled and the odometer shows greater than eight miles. The HVAC Door Recalibration function: - is actuated with the DRBIII(R) After completing HVAC Door Recalibration, the DRBIII(R) will the store the total span and the status of each door actuator. Selecting HVAC Door Cal Monitor in the System Tests will display this information. - homes and repositions door actuators. - monitors for door span faults on the actuator circuits. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - for RS vehicles will cause the Rear Wipe/Wash and RECIRC status indicators on the A/C-Heater Control Module to flash alternately while the test is running. - for RG vehicles will cause the PWR and RECIRC status indicators on the A/C - Heater Control Module to flash alternately while the test is running. The RECIRC status indicator will flash twice per second to indicate that the HVAC Door Recalibration Test needs to be run. The RECIRC status indicator will stop flashing twice per second if either the HVAC Door Recalibration Test returns passed, or if any button on the control is pressed, or if the ignition is cycled and the odometer shows greater than eight miles. The Actuator Circuit Test: - is actuated with the DRBIII(R). - monitors for shorted actuator circuits. - allows service to easily diagnose and troubleshoot up to three simultaneous shorts. - supplements the continuous diagnostics on the actuator drive system. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. When Performing the Actuator Circuit Test CAUTION: - Shorted rear door driver circuits can cause additional Actuator Circuit Test messages to set for circuits where no condition exists to cause a fault. - To ensure a proper diagnosis, repair all Short Too Complex messages first, all rear door driver circuit related messages second, all common door driver circuit related messages third, and all front door driver circuit related messages last. - The DRBIII(R) can display up to three Actuator Circuit Test messages at a time. After repairing each Actuator Circuit Test message, cycle the ignition switch, then rerun the Actuator Circuit Test to ensure no new messages exist. - The Short Too Complex message: indicates that a specific determination of which lines are shorted could not be made. - is caused by more than three drivers being shorted in the same direction. For example, four drivers all shorted to ground, or two or more drivers shorted with at least one driver shorted to ignition/battery and one driver shorted to ground. - Messages displaying: XXX Driver/Circuit Shorted to Ignition/ Battery will set on a per-driver basis. - XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. - the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together.When the test returns passed, then troubleshooting should proceed to clearing faults and running the HVAC Door Recalibration system test as a final check of system health. Instrument Cluster The Instrument Cluster receives and sends messages to other modules via the PCI bus circuit. The indicator lamps will illuminate briefly for a bulb check when the ignition is turned from off to run. All of the gauges receive their information via the PCI bus from the powertrain control module and body control module. The gauges and the LEDs are not individually replaceable thereby requiring complete replacement of the Instrument Cluster if a repair is necessary. In the event that the Instrument Cluster loses communication with other modules on the PCI bus, the cluster will display no bus in the VF display. The Trip/Reset button is used to switch the display from trip to total mileage. Holding the button when the display is in the trip mode will reset the trip Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 441 mileage. This button is also used to put the cluster into self-diagnostic mode. The odometer display uses blue-green vacuum fluorescent digital characters. On base models, the Instrument Cluster has three gauges: Speedometer, fuel and temperature.A red dot appears through openings in the Instrument Cluster face (P-R-N-D-2-1) to indicate the gear selected. With other models, the Instrument Cluster may also include a tachometer and use a vacuum fluorescent shift indicator. The high-line Instrument Cluster features Electroluminescent Illumination of the gauge faces (EL Panel). This feature eliminates the use of bulbs for ,gauge/panel lighting. In a manner similar to fluorescent lights, a/c voltage from an inverter integrated circuit chip is applied to the phosphorescent material, causing it to glow. The phosphorescent material is screen-printed onto flexible Mylar sheets that form the gauge faces. The odometer display and door/liftgate ajar indicators turn on when a door is opened to assist both the customer and service technician to view the odometer without turning the ignition on. On models with AutoStick, the display includes an O/D OFF indicator that is illuminated when the driver presses the Overdrive Off button on the transaxle shifter. INSTRUMENT CLUSTER SELF TEST 1. Depress and hold the Odometer Reset button. 2. Turn the ignition switch to on. 3. Release the Odometer reset button. The Instrument Cluster will illuminate all indicators and step the gauges through several calibration points.Also, the odometer will display any stored codes that may have set. Interior Lighting COURTESY LAMP CONTROL The body controller has direct control over all of the vehicle's courtesy lamps. The body computer will illuminate the courtesy lamps under any of the following conditions: 1. Any door ajar and courtesy lamp switch on the headlamp switch is not in the dome off position. 2. The courtesy lamp switch on the headlamp switch is in the dome on position. 3. A Remote Keyless Entry unlock message is received. 4. Driver door unlocked with key (with VTSS only). ILLUMINATED ENTRY Illuminated entry will be initiated when the customer enters the vehicle by unlocking the doors with the key fob, or with the key if the vehicle is equipped with vehicle theft alarm. Upon exiting the vehicle, if the lock button is pressed with a door open, illuminated entry will cancel when the door closes. If the doors are closed and the ignition switch is turned on, the illuminated entry also cancels. The illuminated entry feature will not operate if the courtesy lamp switch is in the dome off position. INTERIOR LIGHTING BATTERY SAVER If any of the interior lamps are left on after the ignition is turned off, the BCM will turn them off after 8 minutes. To return to normal operation, the courtesy lamps will operate after the dome lamp switch or door ajar switch changes state. The glove box and switched reading lamps require that the ignition be turned to the on/acc position. Memory System The memory system consists of power driver's seat, power mirror, adjustable pedals and radio presets. The Memory Seat/Mirror/Adjustable Pedals Module (MSMAPM) is located under the driver's seat. It receives input from the following: driver's manual 8-way seat switch, driver's seat position sensors, PCI bus circuits, and the power mirror sensors. The module uses these inputs to perform the following functions: position the driver's memory seat, both exterior mirrors (during recalls), both pedals, and send/receive the memory system information over the PCI bus. The Memory Set Switch is wired to the Body Control Module (BCM). A button (either #1 or #2) pressed on the set switch causes the BCM to send a message to the MSMAPM which in turn will send a motion status message back to the BCM. If the message from the MSMAPM indicates no current motion, the BCM will send a recal message to the module. The MSMAPM will set the seat, exterior mirror, pedals, and radio to the presets for the indicated driver. If any one of the memory controlled systems is inoperative from its manual switch, use the schematics and diagnostic information to correct the concern. This manual addresses the memory problems only and it is assumed there is not a basic component failure. POWER SEAT The memory power seat provides the driver with 2 position settings for the driver's seat. Each power seat motor is connected to the MSMAPM with two motor drive circuits. Each circuit is switched between battery and ground. By being able to bidirectionally drive the circuits, the MSMAPM controls the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 442 movement of the motors based on input from the power seat switch or from the position sensors when performing a memory recall. Each motor contains a potentiometer to monitor the seat position. To monitor the position of the motor, the MSMAPM sends out a 5-volt reference on the sensor supply circuit.The sensor is grounded back to the module on a common ground circuit. Based on the position of the sensor, the MSMAPM monitors the voltage change through the sensor on a separate signal circuit. The MSMAPM stores the input value of each of the four seat potentiometers in memory when the system requests a set. The driver can initiate a memory recall, using either the door mounted memory switch or the RKE transmitter (if the remote linked to memory feature is enabled via the EVIC). When initiated, the MSMAPM adjusts the four seat sensors (by using the motors) to match the memorized seat position data. For safety, the memory seat recall is disabled by the MSMAPM when the vehicle is out of park position or if the speed is not zero. Any obstruction to seat movement over a 2-second delay will cause the seat to stop moving in which case a stalled motor would be detected by the MSMAPM and the corresponding seat output would be deactivated. However, if the object obstructing the seat is removed, the seat will function normally again. MEMORY MIRROR The driver side view mirror contains vertical and horizontal bi-directional drive positioning motors and position sensors. The MSMAPM provides a 5-volt reference on the signal circuit to each position sensor. The sensors share a common ground circuit. The MSMAPM monitors the position of the mirror motors by measuring the voltage on each signal circuit. When a memory position is set, the MSMAPM monitors and stores the position of the outside mirror. The MSMAPM adjusts the mirror to the appropriate positions when a memory recall message is received from the RKE or is requested from the memory set switch. The power mirror switch during non-memory operation operates the mirror independently of the MSMAPM. Overhead Console COMPASS/TEMPERATURE MODULE, COMPASS/MINI-TRIP COMPUTER or ELECTRONIC VEHICLE INFORMATION CENTER The Compass/Temperature Module (CT), Compass/Mini-Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) is located in the overhead console. The CT provides the vehicle operator with only outdoor temperature and the compass heading. The CMTC or EVIC supplements the standard vehicle instrumentation. The CMTC and EVIC use a vacuum fluorescent (VF) display to supply the vehicle operator with a compass heading, outdoor temperature, average fuel economy, distance to empty, trip odometer, elapsed ignition on time, distance to service, warning messages, and service messages. The difference between a CMTC and an EVIC is that only the EVIC provides additional memory, feature programming, and warning messages. The EVIC is capable of displaying warning messages and memory system messages when the vehicle is equipped with memory systems. The EVIC also provides the interface to enable and disable vehicle programmable features when the vehicle is equipped with certain features. If equipped, the EVIC is also available with an integrated Universal Garage Door Opener (UGDO) known as HomeLink(R). The EVIC may also be equipped with up to 4 power door switches: ON/ OFF, Left Sliding Door, Right Sliding Door, and Liftgate. The CT function buttons are labeled C/T and US/M. The CMTC function buttons are labeled US/M, C/T, RESET, and STEP. The EVIC function buttons are labeled C/T, RESET, STEP, and MENU. The three UGDO buttons are labeled with dots to indicate the channel number. The BCM supplies most of the information displayed by the CMTC/EVIC. Display information, except for the internal compass function, is received over the PCI bus. The FCM supplies the ambient temperature sensor information via the PCI bus. The CMTC/EVIC sends and receives data over the PCI bus, communicating with the BCM, PCM, FCM, and the Instrument Cluster. Tire Pressure Monitoring System information is received from the SKREEM via PCI bus information. The tire pressure sensors are mounted to the vehicle wheels. For complete information, refer to the Tire Pressure Monitoring System section. VEHICLE INFORMATION DISPLAY The CMTC/EVIC provides the following functions: - Compass direction - Outside temperature - Elapsed ignition on time - Distance to empty - Average fuel economy - Trip odometer - Distance to service The EVIC will also display the following driver alert messages: - TURN SIGNAL ON (with vehicle graphic) - PERFORM SERVICE - DOOR OPEN (individual or multiple doors, with graphic) - LOW TIRE PRESSURE (when equipped) - ADJUSTABLE PEDAL DISABLED CRUISE ENGAGED (when equipped) - ADJUSTABLE PEDAL DISABLED VEHICLE IN REVERSE (when equipped) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 443 An audible chime or chimes will accompany any displayed warning messages. Chime requests with an OPEN message are dependent upon vehicle speed. The CT/CMTC/EVIC will not display information for any of the screens for which it did not receive the proper PCI bus data. Refer to the symptom list in the Overhead Console section for problems related to the CT/CMTC/EVIC. The CMTC/EVIC receives the following messages from the Body Control Module (BCM): - Verification of US/Metric status - VF display dimming brightness and exterior lamp status - Elapsed Ignition On Time data - Average Fuel Economy - Distance to Empty - Distance to service - Driver warning messages The CT/CMTC/EVIC receives the following messages from the Front Control Module (FCM): - Outside Temperature The CMTC/EVIC receives the following messages from the Powertrain Control Module (PCM): - Trip Odometer data - Vehicle Speed The EVIC receives the following messages from the Adjustable Pedal System Module (APS): - APS status warnings The CT/CMTC/EVIC receives the following messages from the Sentry Key Remote Electronic Entry Module (SKREEM): - Tire Pressure information The CMTC/EVIC transmits the following messages to the BCM: - Status Request: Beep, Reset, US/M Toggle - Current Display STEP BUTTON The STEP Button can be used in one of the following three ways: 1. To sequentially select one of seven displays or blank display in the following order: - Average Fuel Economy - Distance to Empty - Trip Odometer - Time Elapsed - Distance to Service Message - Off (Blank) 2. To set the magnetic variance zone when VARIANCE = X (X = 1 - 15) is indicated in the VF Display. 3. To select the displayed programmable feature setting. (When equipped.) MENU BUTTON (EVIC only) For complete information of the programmable features and memory messages. Use the MENU button to sequentially step the EVIC through the programmable features. MENU BUTTON (EVIC only) For complete information of the programmable features and memory messages.Use the MENU button to sequentially step the EVIC through the programmable features. RESET BUTTON The RESET Button has two different functions: 1. To clear the trip functions that may be reset 2. To enter and exit the diagnostic mode Pressing the RESET button once will clear the trip function that is currently being displayed (except Distance to Service) and the CMTC/EVIC will send a PCI bus beep request to the BCM. If the RESET button is pressed again within 3 seconds, the CMTC/EVIC will reset ALL of the trip functions and an additional beep request is sent to the BCM. The trip functions that may be reset are: - Average Fuel Economy - Trip Odometer - Elapsed Time Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 444 A reset will only occur if one of the trip functions that may be reset is currently being displayed. Pressing the RESET button for more than three (3) seconds resets the Distance to Service function while the Distance to Service message is being displayed. The CMTC/EVIC module will send a beep request to the BCM. Simultaneously pressing the RESET button and the STEP button while turning the ignition from Off to On will enter the CMTC/EVIC into the self-diagnostic mode. COMPASS/TEMPERATURE (C/T) BUTTON Actuating the Compass/Temperature Button (C/T) will cause the CMTC/EVIC to display the compass and temperature information. This function will operate from another traveler display or from the programmable feature mode. TRAVELER DISPLAY FUNCTIONS Using the STEP button will change the CMTC/ EVIC between modes of operation and display the appropriate information according to data received from the PCI Bus. COMPASS/TEMPERATURE The CMTC/EVIC simultaneously displays the compass reading and the outside temperature. Outside temperature information is received via the PCI bus from the FCM. The CMTC/EVIC module internally senses and calculates the compass direction. COMPASS OPERATION - ALL Upon ignition on, if the calibration information stored in the CMTC memory is within the normal range, the CMTC will perform in slow Auto-Cal mode. In slow Auto-Cal mode, the CMTC continuously compensates for the slowly changing magnetic field of the vehicle. The compass module detects changes in the vehicle magnetism and makes appropriate internal corrections to ensure proper displayed direction. However, if the calibration information stored in the CMTC memory is not within the normal range at ignition on, the CMTC will enter fast Auto-Cal. CAL is displayed along with the temperature. Auto activation of the fast Auto-Cal mode will also occur when the CMTC is subjected to high magnetic field strength levels, which cause all compass readings to be erroneous for a continuous period of five (5) minutes. During fast Auto-Cal, CAL will be displayed along with the temperature. Fast Auto-Cal can also be performed manually, by pressing and holding the RESET button for 10 seconds during the Compass/Temperature display mode. SETTING MAGNETIC ZONE VARIANCE Variance is the difference between magnetic North and geographic North. For proper compass function, the correct variance zone must be set. Refer to the Zone Variance map for the correct zone. Follow these steps to check or change the variance zone: CMTC/EVIC: - The ignition switch must be in the On position and the CMTC/EVIC display must not be blank. - If the compass/temperature data is not currently being displayed, momentarily press and release the C/T button to display compass/temp information. - Press and hold the RESET button (approximately 5 seconds) until VARIANCE = XX is displayed. The CMTC/EVIC will display the variance zone stored in memory and the word VARIANCE. - Use the RESET button to select the proper variance zone number, 1 through 15. - After selecting the proper zone number, momentarily press and release the RESET button. The variance zone is then stored in the memory and the CMTC/EVIC returns to normal operation. CT: - The ignition switch must be in the On position and the C/T display must not be blank. Press and hold the C/T and US/M buttons (approximately 5 seconds) until VARIANCE = XX is displayed. The C/T will display the variance zone stored in memory and the word VARIANCE. - Use the US/M button to select the proper variance zone number, 1 through 15. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 445 - After selecting the proper zone number, momentarily press and release the C/T button. The variance zone is then stored in the memory and the C/T returns to normal operation. COMPASS CALIBRATION The compass module has 2 types of auto calibration; slow-cal and fast-cal. Slow-cal ensures that during normal vehicle operation th0e compass performs auto-calibration functions to keep the compass sensors in their proper operating range. Whenever the ignition is On and the CT/CMTC/ EVIC receives PCI bus data indicating that engine RPM is greater than zero, auto-calibration is performed continuously. If the calibration information stored in the compass module memory is not within the normal range after a power-up cycle, the compass will display CAL. The CT/CMTC/EVIC will enter into the fast-cal mode until calibration is complete. To enter the compass into Manual Calibration mode, perform the following steps: - Drive the vehicle to an area away from any large metal objects or overhead power lines. - Ensure that the proper variance zone is selected. See "Setting Magnetic Zone Variance". - The ignition switch must be in the On position and the CMTC/EVIC display must not be blank. - Press the C/T button to view the Compass/ Temperature display. - Press and hold the RESET button (approximately 10 seconds) until CAL is displayed, then release the button. - Drive slowly, less than 5 MPH (8 KPH) in at least 1 complete 360-degree circle. - CAL will remain illuminated to alert the driver that the compass is in the calibration mode. - After calibration is complete, CAL will turn off. NOTE: For C/T Manual Calibration, perform the same procedure as above, but press and hold the C/T and US/M buttons until CAL is displayed. If the compass appears blank, unable to be calibrated, or the compass displays false indications,the vehicle must be demagnetized. SELF-CHECK DIAGNOSTICS The CT/CMTC/EVIC is capable of performing a diagnostic self check on its internal functions. Diagnostics may be performed using a DRBIII(R) or by using the following procedure: 1. For CMTC/EVIC: With the ignition switch in the OFF position, depress and hold the RESET and the STEP buttons. For CT: With the ignition switch in the OFF position, depress and hold the C/T and the US/M buttons. 2. Turn the ignition switch to the ON position. 3. Continue to hold both buttons until the software versions are displayed, then release the buttons. 4. All of the VFD segments will illuminate for 2-4 seconds. Check for segments that do not illuminate or illuminate all the time. 5. When the self-check is complete the EVIC will display one of the following messages: - PASS SELF TEST - FAILED SELF TEST - NOT RECEIVING J1850 MESSAGE When the self-check is complete the CT/CMTC will display one of the following messages: - PASS - FAIL - BUS 1. To exit the self-check mode: For the CMTC/EVIC: Depress the STEP or RESET button, or cycle the ignition switch and the CMTC/EVIC will return to normal operation. For the C/T: Depress the C/T or US/M button, or cycle the ignition switch and the CT will return to normal operation. If a Communication fault is displayed, refer to the symptom list. If a FAIL or FAILED is displayed, the CT/CMTC/EVIC must be replaced. AMBIENT TEMPERATURE SENSOR Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 446 The ambient air temperature is monitored by the FCM and displayed by the CT/CMTC/EVIC. The FCM receives a hardwire input from the ambient temperature sensor (ATS). The ATS is a variable resistor that operates on a 5-volt reference signal circuit hardwired from the FCM. The resistance in the ATS changes as the outside temperature rises or falls. The FCM senses the change in reference voltage through the ATS resistor. Based on the resistance of the ATS, the FCM is programmed to correspond to a specific temperature. The FCM stores and filters the ambient temperature data and transmits this data to the CMTC/EVIC via the PCI Bus. The ATS cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. AMBIENT TEMPERATURE SENSOR FAULT CODES The outside temperature function is supported by the ambient temperature sensor (ATS), a signal and ground circuit hardwired to the FCM, and the CMTC/EVIC display. If the ATS sense circuit is shorted to ground, the temp display will be 54° C (130° F) to indicate SHORT circuit condition. If the ATS sense circuit is open, the temp display will be -40° C (-40° F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the CMTC/EVIC VFD can be tested. The ATS is supported by the FCM. Ambient Temperature Sensor DTC's will be recorded in the FCM. The ATS can be diagnosed using the following Sensor Test. Test the ATS circuits using the diagnostics in the Body Diagnostic Procedures Manual. If the CMTC/EVIC passes the self-test, and the ATS, the circuits, and PCI bus communications are confirmed to be OK, but the CMTC/EVIC temperature display is inoperative or incorrect, replace the FCM. AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: - 0° C (32° F) Sensor Resistance = 29.33 - 35.99 Kilohms - 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kilohms - 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kilohms - 25° C (77° F) Sensor Resistance = 9.12 - 10.86 Kilohms 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kilohms - 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance values are not OK, replace the Sensor. HOMELINK(R) UNIVERSAL TRANSMITTER If equipped, HomeLink(R) Universal Transmitter is integrated into the overhead console. For added security it will operate home security systems that use coded signals known generically as Rolling Codes. The overhead console display provides visual feedback to the driver, indicating which HomeLink(R) transmitter channel button is being pressed. The HomeLink(R) can learn and store up to three separate transmitter radio frequency codes to operate garage door openers, security gates, and security lighting. The HomeLink(R) buttons are marked with one, two, or three dots. For complete information. TIRE PRESSURE MONITORING SYSTEM (TPMS) If equipped with the Tire Pressure Monitoring System (TPMS), each of the vehicles four wheels will have a valve stem with a pressure sensor and radio transmitter built in. Signals from the tire pressure Sensor/Transmitter are received and interpreted by the Sentry Key Remote Entry Module (SKREEM). Using the DRBIII(R), go to ANTI-THEFT for the SKREEM data. A Sensor/Transmitter in a mounted wheel will broadcast an RF frequency indicating its pressure once per minute when the vehicle is in drive mode. To activate the Sensor/Transmitter operation, the required SKREEM speed is 13 mph (20 km/h). Each Sensor/Transmitters broadcast is uniquely coded so that the SKREEM can monitor the states of each Sensor/Transmitter on the vehicle. The SKREEM TPMS does not use a magnet to relearn, it automatically learns while driving after a SKREEM or a Sensor/Transmitter has been replaced. TRAINING THE SKREEM If a Sensor/Transmitter is replaced, the vehicle has to be parked for at least 15 minutes for the system to be ready to learn the new Sensor/Transmitter ID code. The vehicle then must be driven for a minimum of five minutes with a minimum continuous speed above 13 mph (20 km/h). The system will learn the new Sensor/Transmitter and clear the DTC's automatically. The Sensor/ Transmitters are programmed at the assembly plant in this clockwise orientation: Sensor/Transmitter 1 = Left Front Sensor/Transmitter 2 = Right Front Sensor/Transmitter 3 = Right Rear Sensor/Transmitter 4 = Left Rear NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 447 1. If one or all Sensor/Transmitters cannot be trained, check for and avoid RF interference. 2. If one Sensor/Transmitter still cannot be trained, replace it and retry. 3. If all Sensor/Transmitters still fail to train, replace the SKREEM. PRESSURE THRESHOLDS The SKREEM will monitor the tire pressure signals from the Sensor/Transmitters and determine if any tire has gone below the low-pressure or above the high-pressure thresholds. Refer to the tables below: Low Tire Pressure Thresholds High Tire Pressure Thresholds *Tolerance ±6.9 kPa (1 PSI) ACTIVE FAULT AND SYSTEM ALERTS An active fault will be triggered when a system failure has been detected. When this occurs, the Instrument Cluster will illuminate the TPMS indicator and the SKREEM will store the fault code. An alert will be triggered when a tire pressure has gone below or above the set threshold pressure. When this occurs, the Instrument Cluster will flash the TPMS indicator. The SKREEM will request a secondary message to be displayed on the EVIC (if equipped). Only when a tire pressure has gone below the set threshold pressure will the SKREEM request the TPMS indicator to flash and display the EVIC message (if equipped). When a high pressure alert occurs, only the EVIC message will be displayed. This action will be displayed as long as the alert condition is active. Park Assist System The Park Assist System display activates an audible tone that changes from intermittent to continuous as the final two Light Emitting Diodes (LED's) are illuminated on one side or both sides of the display. The system detection length from the rear of the vehicle is 0.3 meters to 1.5 meters. This area extends around the rear side of the vehicle.The system detection height from the ground is 0.2 meters to about 1.5 meters. The radio mutes when the system activates its audible tone. When the driver selects Reverse or Neutral the system scans for objects behind the vehicle using four sensors located in the rear bumper. Objects can be detected from up to 1.5 meters. A warning display above the rear window provides both visible and audible warnings indicating the range of the object. The system is active only when the vehicle is in reverse or neutral for vehicle speeds less than 16 Km/h (10 mph). If the vehicles Parking/Emergency Brake is applied, the system is deactivated. The display contains two sets of yellow and red Light Emitting Diode's (LED's) that the driver can see in the rear view mirror. Each side of the vehicle has its own warning LED's. The system provides a visual warning by illuminating one or more yellow LED's as the vehicle gets closer to the object. As the vehicle continues to approaches the object, one red LED is illuminated and the system emits a series of short beeps. The tone will remain constant and both red LED's are illuminated once the vehicle is within 12 inches (30.5 cm) of the object. The system can be turned ON or OFF through the Electronic Vehicle Information Center (EVIC) when the vehicle is in PARK. If the park assist system is turned OFF, a single chime will sound and the EVIC will display the following message REAR PARK ASSIST OFF, when the vehicle is in reverse. - Ensure that the rear bumper is free of dirt and debris to keep the system operating properly. - Jackhammers, large trucks, and other vibrations could affect the performance of the system. - Ensure that the parking brake is not applied. If Service Park Assist System appears in the EVIC after making sure the rear bumper is clean, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 448 proceed to diagnose the system using a scan tool and the appropriate diagnostic information. Power Door Lock System When the BCM receives input for a lock request from a door lock switch, RKE or cylinder lock switch (only with VTSS), it will turn the lock drivers on for a specified time of 375 msec. If the request is there beyond 375 msec, the BCM considers the door lock signal stuck. Once a door lock or unlock signal is stuck for longer than 10 seconds, the BCM will set a trouble code and the signal input is ignored until the stuck condition disappears. The door lock switches provide a variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond to that command. DOOR LOCK INHIBIT When the key is in the ignition and in any position and either front door is open, the door lock switches LOCK functions are disabled. The UNLOCK functions are still functional. This protects against locking the vehicle with the keys still in the ignition. The RKE key fob will still lock the doors as usual. After the key is removed from the ignition or the doors are closed, the power door locks will operate normally. AUTOMATIC DOOR LOCKS This feature can be enabled or disabled by using either the DRBIII(R) or the customer programming method. When enabled all the doors will lock when the vehicle reaches a speed greater than 18 MPH (29 KMH) and all the doors are closed. If a door is opened and the vehicle slows to below 18 MPH (29 KMH), the door locks will operate again once all doors are closed and the speed is above 18 MPH (29 KMH). REMOTE KEYLESS ENTRY (RKE) The RKE transmitter uses radio frequency signals to communicate with the SKREEM module. The SKREEM is on the PCI bus. When the operator presses a button on the transmitter, it sends a specific request to the SKREEM. In turn the SKREEM sends the appropriate request over the PCI Bus to the: - Body Control Module (BCM) to control the door lock and unlock functions, the arming and disarming of the Vehicle Theft Security System (if equipped), and the activation of illuminated entry. - Integrated Power Module (IPM) to activate the park lamps, the headlamps, and the horn for horn chirp. - Power Liftgate Module (PLGM) to control the liftgate operation (double press). - Power Sliding Door Module (PSDM) to control the sliding door operation (double press). After pressing the lock button on the RKE transmitter, all of the door locks will lock, the illuminated entry will turn off (providing all doors are closed), and the vehicle theft security system (if equipped) will arm. After pressing the unlock button, on the RKE transmitter, one time, the driver doorlock will unlock, the illuminated entry will turn on the courtesy lamps, and the vehicle theft security system system (if equipped) will disarm. After pressing the unlock button a second time, the remaining door locks will unlock. The EVIC or the DRBIII(R) can reprogram this feature to unlock all of the door locks with one press of the unlock button. If the vehicle is equipped with the memory system, the memory message will identify which transmitter (1 or 2) sent the signal. The SKREEM is capable of retaining up to 8 individual access codes (8 transmitters). If the PRNDL is in any position except park, the SKREEM will disable the RKE. The 3 or 6 button transmitter uses 1-CR2032 battery. The minimum battery life is approximately 5 years based on 20 transmissions a day at 84° F (25° C). Use the DRBIII(R) or the Miller Tool 9001 RF Detector to test the RKE transmitter. Use the DRBIII(R) or the customer programming method to program the RKE system. However, the SKREEM will only allow RKE programming when the ignition is in the on position, the PRNDL is in park position, and the VTSS (if equipped) is disarmed. PANIC FUNCTION Pressing the panic button on the RKE transmitter will cause the headlamp relay, the park lamp relay, and the horn relay to pulsate, which in turn will cause the exterior lamps to flash and the horn to sound intermittently. It will also cause the courtesy lamp relay to actuate, turning on the courtesy lamps. Pressing the panic button again stops the headlamps and the park lamps from flashing and the horn from sounding. However, the courtesy lamps will remain on until either the BCM times out lamp operation or until the ignition is turned on. The panic feature operates for three minutes at a time, unless the operator cancels it, or the ignition is turned on. Actuating the headlamp, horn, park lamps, and courtesy lamps with the DRBIII(R) will verify if the circuits and the Integrated Power Module are OK. If the panic feature is still inoperable with all transmitters, it will be necessary to replace the SKREEM. If the function is inoperable with just one transmitter, then replace only that transmitter. ROLLING CODE The rolling code feature changes part of the transmitter message each time that it is used. The transmitter message and the receiver message increment together. Under certain conditions with a rolling code system (pressing a button on the RKE transmitter over 255 times outside the receiver range, battery replacement, etc.), the receiver and transmitter can fall out of synchronization. NOTE: The lock function works from the RKE transmitter even in an out of synchronization condition and therefore it could be verified by pressing the LOCK button on the RKE integrated key. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 449 To resynchronize, press and release the UNLOCK button on the RKE transmitter repeatedly (it may take up to eight cycles) while listening carefully for the power door locks in the vehicle to cycle, indicating that resynchronization has occurred. PROGRAMMABLE DOOR LOCK FEATURES - The RKE can be changed to unlock all doors with one press - The Automatic Door Locks can be enabled/ disabled - Auto Unlock on Exit can be enabled/disabled - RKE horn chirp on lock can be enabled/disabled - RKE optical chirp (turn signal lamps) can be enabled/disabled - Program a new RKE transmitter. - RKE linked to memory (if equipped with memory system) enabled/disabled (DRBIII(R) only). Allows memory to be operable only from the driver door switch. Rear Window Defog/Heated Mirror The defroster button located on the HVAC control controls the rear window defogger and the heated side view mirrors. When the defroster button is pushed, the HVAC control sends a bus message over the PCI bus to the Front Control Module (FCM) which controls the Rear Window Defogger relay. The defroster LED will illuminate when the defroster function is on. The defroster will function for 10 minutes or can be cycled off sooner by pressing the defroster button again. Vehicle Theft Security System The Vehicle Theft Security System (VTSS) is part of the Body Control Module (BCM). The BCM monitors the vehicle doors, liftgate (export only), hood (export only), and the ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps and the VTSS indicator lamp. The VTSS does not prevent engine operation, this is done with the Sentry Key Remote Entry Module (SKREEM). The VTSS indicator lamp will flash for approximately 15 seconds during the arming process. If there is no interruption during the arming process, upon completion the VTSS indicator lamp will flash at a slower rate. When the BCM receives an input to trigger the alarm, the BCM will control the outputs of the headlamps, horn, and VTSS lamp for approximately 15 minutes. Arming (Active and Passive) Active arming occurs when the ignition key is removed, the RKE transmitter or door key cylinders are used to lock the vehicle doors, whether the doors are open or closed. The arming process is complete only after all doors are closed. Passive arming occurs when the ignition key is removed, the driver door is opened, and the doors are locked with the power door lock switch, and the door is closed. Disarming (Active and Passive) Active disarming occurs when the RKE transmitter is used to unlock the vehicle doors. This disarming will also halt the alarm once it has been activated. Passive disarming occurs upon normal vehicle entry (unlocking driver door with the key) or turning the ignition switch on with a valid ignition key. This disarming will also halt the alarm once it has been activated. Tamper Alert The VTSS tamper alert will sound the horn three times upon disarming after an initial alarming has occurred to indicate a tamper condition has occurred. Manual Override The system will not arm if the doors are locked using the manual lock control or if the locks are actuated by an inside occupant after the doors are closed. Diagnosis For complaints about the Vehicle Theft Alarm triggering on its own, use the DRBIII(R) and read the Last VTSS Cause status. Arming Before arming, all doors, liftgate, and the hood must be completely closed. The system can only be armed by locking the doors with the RKE transmitter. Disarming To disarm the alarm system, use the RKE transmitter or turn the ignition on with a valid ignition key. This will also halt the alarm once it has been activated. NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes on after ignition on and stays on, the PCI Bus Communication with the powertrain Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 450 control module has possibly been lost. Power Folding Mirrors The power folding mirrors are powered to two positions: folded and unfolded. The driver may choose fold or unfold with a switch that is located on the right side of the steering column. The folding mirror switch grounds a sense wire that comes from the Body Control Module when it is placed in the fold position. The mirrors will move to the position designated by the switch whether the ignition switch is the On or Off position and both front doors are closed. When the Power Folding Mirror switch is left in the fold position during a vehicle exit the mirrors will automatically unfold then refold after both front doors are closed. This is to prevent mirror contact with either front door when opened. When opening either front door, the Body Control Module will unfold the mirrors in the following manner depending on which front door is opened. If the driver door is opened, only the driver side mirror will unfold. If the passenger door is opened, both mirrors will unfold. The passenger mirror is prevented from unfolding when the driver's door is opened by the Passenger Folding Mirror Relay, which opens the driver circuit to the passenger side mirror. Power Liftgate System POWER LIFTGATE The power liftgate (PLG) system is activated through the use of the following: remote keyless entry (RKE), overhead console switches, outside liftgate handle switch or the DRBIII(R). These inputs are hardwired to the body control module (BCM) and can be monitored with a diagnostic tool. The BCM will send the message via PCI bus to the power liftgate module (PLGM). The liftgate must be in the full open or full closed position to operate. Once the BCM sends a button activation message to the PLGM, the module shall read all inputs, outputs and vehicle conditions to determine whether it shall open, close or inhibit the PLG operation. Once the PLGM determines the vehicle conditions are safe for operation, the PLGM will initiate a chime for 2 seconds prior to the liftgate activation and 2 seconds during the open or close cycle. During an opening or closing cycle, the PLGM can detect an obstacle present should it meet sufficient resistance by the hall effect sensors (integrated in the gear motor assembly GMA).During an open cycle, multiple liftgate activations (RKE, overhead console, B pillar) are ignored until the liftgate reaches the full open position. However, during a close cycle, a 2nd liftgate activation (RKE, overhead console, B pillar) will reverse the liftgate to the full open position. If the engine is cranked during a power open/close the PLG will pause then resume after engine cranking. In addition, if the vehicle is placed in gear during an open cycle, the PLG shall reverse direction and begin closing. If the vehicle is placed in gear during a closing cycle, the PLG shall continue closing until fully closed. If the outside handle is activated during an open cycle, the PLG will become a full manual liftgate. If the outside handle is activated during a close cycle, the PLG shall reverse direction of travel to the full open position. DIAGNOSTIC FEATURES The PLG can be flashed on vehicle via PCI bus with a DRBIII(R) diagnostic tool. The DRBIII(R) can read all inputs, actuate all outputs, read module information, and read diagnostic trouble codes. As a reminder, some DTC's can be set during normal PLG operation. SYSTEM INHIBITORS 1. Battery voltage too high or too low (above 16 V, below 9.5 V) 2. Vehicle in gear 3. Vehicle speed > 0 mph/km/h 4. Outside temperature too high, above 143° F (62° C) or too low, below -12° F (-24° C). 5. O/H console lockout will inhibit the B pillar switches only. 6. Liftgate locked will inhibit all interior switches from opening (overhead console). A locked liftgate can be power closed. 7. Pinch Sensor switch stuck shall inhibit the power close feature. Power Sliding Door System POWER SLIDING DOOR The Power Sliding Door (PSD) system is activated through the use of the following: Remote Keyless Entry (RKE), overhead console switches, B pillar switches or the DRBIII(R). These inputs are hardwired to the body control module (BCM) and can be monitored with a diagnostic tool. The BCM will send the message via PCI bus to the power sliding door module (PSDM). The sliding door must be in the full open or full closed position to operate. Once the BCM sends a button activation message to the PSDM, the module shall read all inputs, outputs and vehicle conditions to determine whether it shall open, close or inhibit the PSD operation. During an opening or closing cycle, the PSDM can detect an obstacle present should it meet sufficient resistance by the hall effect sensors (integrated in the drive motor). During an open cycle, multiple door activations (RKE, overhead console, B pillar) are ignored until the door reaches the full open position. However, during a close cycle, a 2nd door activation (RKE, overhead console, B pillar) will reverse the door to the full open position. If the engine is cranked during a power open/close the PSD will pause then resume after engine cranking. In addition, if the vehicle is placed in gear during an open cycle, the PSD shall reverse direction and begin closing. If the vehicle is placed in gear during a closing cycle, the PSD shall continue closing until fully closed. If the inside or outside handle is activated during an open or close cycle, the PSD will become a full manual sliding door. The child lockout is mechanical only and has no effect on the B-pillar switch as it did in previous models. There is only one part number for the power sliding door module (PSDM). The driver sliding door harness has an additional ground circuit which will Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 451 identify it as the driver side. This eliminates the need for a left and a right side module. DIAGNOSTIC FEATURES The PSDM can be flashed on vehicle via PCI bus with a DRBIII(R) diagnostic tool. The DRBIII(R) can read all inputs, actuate all outputs, read module information, and read diagnostic trouble codes. As a reminder, some DTC's can be set during normal PSD operation. SYSTEM INHIBITORS 1. Battery voltage too high or too low (above 16 V, below 9.5 V) 2. Vehicle in gear 3. Vehicle speed > 0 mph/km/h 4. O/H console lockout will inhibit the B pillar switches 5. Doors locked will inhibit all interior switches from opening (Overhead Console, B Pillar). A locked sliding door can be power closed. Wiper System FRONT WIPER The front wiper/washer system consists of the following features: lo-hi-speed, mist wipers, intermittent wipers and wipe after wash. The front wiper system is only active when the ignition switch is in the RUN/ACC position. The vehicle operator selects the front wiper function using the front wiper switch (a resistive multiplexed stalk switch) which is integral to the Multi-Function Switch. The front wiper switch is hardwired to the Body Control Module (BCM). Upon receiving a wiper switch signal, the BCM sends a PCI Bus message to the Front Control Module (FCM). The FCM controls the ON/ OFF relay, the HIGH/LOW relay and the front and rear washer pump motors. The Wiper system utilizes the BCM to control the on/off and hi/low relays for the low and hi speed wiper functions, intermittent wiper delay as the switch position changes, pulse wipe, wipe after wash mode and wiper motor functions. The BCM uses the vehicle speed input to double the usual delay time below 10 MPH (16 KPH). SPEED SENSITIVE INTERMITTENT WIPE MODE There are 5 individual delay time settings with a minimum delay of 1.7 seconds to a maximum of 18.4 seconds. When the vehicle speed is under 10 MPH (16 KPH), the delay time is doubled, providing a delay range of 3.4 seconds to 36.8 seconds. PULSE WIPE When the wiper is in the off position and the driver presses the wash button for more than 0.062 seconds, but less than 0.5 seconds,2 wipe cycles in low speed mode will be provided. PARK AFTER IGNITION OFF Because the wiper relays are powered from the battery, the BCM can run the wipers to park after the ignition is turned off. WIPE AFTER WASH When the driver presses the wash button for over 0.5 seconds and releases it, the wiper will continue to run for 2 additional wipe cycles. REAR WIPER The rear wiper/washer system consists of the following features: mist wipers, intermittent wipers and wipe after wash. The rear wiper system is only active when the ignition switch is in the RUN/ACC position. The vehicle operator selects the rear wiper function using one of the three buttons on the dash mounted rear wiper switch. The rear wiper switch is hardwired to the Body Control Module (BCM). Upon receiving a wiper switch signal, the BCM provides 12 volts to the rear wiper motor. Rear washer occurs when the BCM receives a rear washer switch ON input. The BCM sends a PCI Bus message to the FCM requesting rear washer on. The FCM activates the rear washer by providing a ground for the rear washer motor. SPEED SENSITIVE INTERMITTENT WIPE MODE The delay setting of the rear wiper system is based solely on the vehicle speed. The delay time is defined as the amount of time from the start of a wipe to the beginning of the next wipe. The rear wiper system delay time is based on the following: 7.75 - (MPH x 0.05) = Seconds delay Examples:At zero (0) MPH the delay is 7.75 seconds. At 100 MPH the delay is 2.75 seconds. WIPE AFTER WASH When the driver presses the wash button for over 1.5 seconds and releases it,the wiper will continue to run for 2 additional wipe cycles. Telecommunications HANDS FREE PHONE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 452 OVERVIEW The vehicle telecommunications system consists of a Hands Free Module, Rear View Mirror, and a Blue-tooth Hands Free Profile enabled cell phone. The system allows vehicle occupants to use voice recognition technology to make, receive and screen phone calls without physically handling a cell phone. The system has a programmable phone book that can prevent the vehicle operator from becoming distracted searching for a specific number. Seven different wireless phones can be programmed to operate each individual system. Each of the seven phones is given a rank of priority when programmed. OPERATION Incoming phone messages are transmitted to the vehicle occupants through the vehicles audio system when the ignition is on and the wireless phone is on. Upon receiving the signal from an incoming phone call, the vehicle audio system will fade out the current CD/DVD or radio output. The vehicle occupants are then directed to accept or reject the call.Outgoing audio messages are received through the microphone located in the rearview mirror then transmitted via hardwire to the Hands Free Module and finally transmitted through the wireless phone. Volume of the voice prompts and incoming conversation is controlled using the vehicles radio audio controls and steering wheel controls if equipped. The rear view mirror contains a Phone Switch, Voice Recognition Switch and a microphone. The rear view mirror transmits these inputs via hardwired circuits to the Hands Free Module. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Air Bag System Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Any Station Preset Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 455 Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 456 POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Test 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 457 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Pause/Play Switch Inoperative Test 1 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 458 Test 1 SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Remote Radio Controls Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 459 Test 4 - 7 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 460 Test 8 - 9 SYMPTOM REMOTE RADIO CONTROLS INOPERATIVE POSSIBLE CAUSES - Open radio control MUX circuit at the switch - Open radio control MUX return circuit at the switch - Remote radio switch - Body control module - internal short - Open clockspring - Open radio control MUX circuit - Open radio control MUX return circuit - Body control module - open internal Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 461 Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 462 POSSIBLE CAUSES - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure ATC Head LED(s)/Backlighting Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 463 Test 1 - 3 Test 4 - 5 SYMPTOM ATC HEAD LED(S)/BACK LIGHTING INOPERATIVE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 464 POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - ATC - LED(s) inoperative - ATC - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 465 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 466 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 467 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 468 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 469 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM FUSE #10 - Fused front blower motor relay output circuit shorted to ground - Blower motor shorted to ground - Front blower power module shorted to ground - Ground circuit open - Blower motor control circuit shorted to voltage - Blower motor control circuit open - Front blower power module open - Automatic temperature control module open - Check blower motor operation - Front blower power module open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 470 Test 1 Test 2 SYMPTOM FRONT BLOWER RUNS AT ONLY ONE SPEED Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 471 POSSIBLE CAUSES - Blower motor control circuit shorted to ground - Automatic temperature control module - Front blower power module HVAC System Test Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 472 Test 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 473 Test 6 Test 7 SYMPTOM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 474 HVAC SYSTEM TEST POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active ATC DTC's - Check for AC cooldown test fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear ATC Switch LED(s)/Backlighting Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 475 Test 4 - 5 SYMPTOM REAR ATC SWITCH LED(S)/BACK LIGHTING INOPERATIVE POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - Rear ATC switch - LED(s) inoperative - Rear ATC switch - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 476 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 477 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 478 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 479 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 480 Test 15 - 16 SYMPTOM REAR BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM Fuse #12 - Fused rear blower relay output circuit shorted to ground - Blower motor shorted to ground - Rear blower motor power module shorted to ground - Ground circuit open - Rear blower motor control circuit shorted to voltage - Rear blower motor control circuit open - Rear blower motor power module open - Automatic temperature control module open - Check blower motor operation - Rear blower motor power module open - IPM - open circuit - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 481 Test 1 Test 2 SYMPTOM REAR BLOWER RUNS AT ONLY ONE SPEED POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 482 - Rear blower motor control circuit shorted to ground - Automatic temperature control module - Rear blower motor power module Chime Inoperative Test 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE POSSIBLE CAUSES - Use DRB to actuate chime - Chime driver circuit - open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 483 - Chime driver circuit - short to ground - Chime driver circuit - short to voltage - Instrument cluster - BCM Key In Ignition and Drivers Door Open Chime Not Operating Properly Test 1 - 3 SYMPTOM KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME NOT OPERATING PROPERLY POSSIBLE CAUSES - DRB chime actuator - Driver door ajar status - Ignition switch - Body control module Vehicle Speed Warning Chime Problem Test 1 SYMPTOM PROBLEM WITH THE VEHICLE SPEED WARNING CHIME POSSIBLE CAUSES - Incorrect country code programmed in BCM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 484 - Body control module Left Front Door Ajar Switch Sense Circuit Open Test 1 - 4 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Left front door ajar switch ground circuit open - Left front door (lock motor) ajar switch - Left front door ajar switch sense circuit open - Body control module internal malfunction Left Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 485 Test 1 - 2 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left front door (lock motor) ajar switch shorted to ground - Left front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Left Sliding Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 486 Test 1 - 3 Test 4 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Left sliding door ajar switch sense circuit open - Left sliding door ajar switch sense circuit open - Body control module internal malfunction Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 487 - Left sliding door lock motor/ajar switch (latch assy). Left Sliding Door Ajar Switch Sense Circuit Shorted to Ground Test 1 - 3 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left sliding door lock motor/ajar switch shorted to ground - Left sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Left sliding door lock motor/ajar switch (latch assy). Liftgate Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 488 Test 1 - 4 SYMPTOM LIFTGATE AJAR CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Liftgate ajar switch ground circuit open - Liftgate ajar switch (cinch/release motor) - Liftgate ajar switch sense circuit open - Body control module internal malfunction Liftgate Ajar Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 489 Test 1 - 2 SYMPTOM LIFTGATE AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Liftgate ajar switch shorted to ground - Liftgate ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 490 Test 1 - 4 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Right front door ajar switch ground circuit open - Right front door (lock motor) ajar switch - Right front door ajar switch sense circuit open - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 491 Test 1 - 2 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right front door (lock motor) ajar switch shorted to ground - Right front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Sliding Door Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 492 Test 1 - 3 Test 4 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Right sliding door ajar switch sense circuit open - Right sliding door ajar switch sense circuit open - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 493 Right Sliding Door Ajar Circuit Shorted to Ground Test 1 - 3 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right sliding door lock motor/ajar switch shorted to ground - Right sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) A/C Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 494 Test 1 - 2 Test 3 SYMPTOM A/C STATUS INDICATOR FLASHING - MTC POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Blend/Mode/Recirc Door Operation Improper -- Dual & Three-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 495 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 496 Test 4 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 497 Test 7 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 498 Test 10 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER -- DUAL & THREE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Passenger blend door actuator/linkage/door - Driver blend door actuator/linkage/door - Recirculation door actuator/linkage/door - Rear mode door actuator/linkage/door - Rear blend door actuator/linkage/door Blend/Mode/Recirc Door Operation Improper --Single-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 499 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 500 Test 4 - 7 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER --SINGLE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Blend door actuator/linkage/door - Recirculation door actuator/linkage/door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 501 Front A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Test 4 SYMPTOM FRONT A/C - HEATER CONTROL ILLUMINATION INOPERATIVE -MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - A/C - heater control module - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 502 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 503 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 504 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 505 Test 11 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 506 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #10 - Fused front blower motor relay output circuit shorted to ground - Front blower motor resistor block shorted to ground - Front blower motor resistor block shorted to ground - Blower motor - Blower motor - A/C - heater control module - Ground circuit open - Blower motor high driver circuit open - Front blower motor resistor block open - Front blower motor resistor block open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Motor Speeds Incorrect - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 507 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 508 Test 3 - 5 SYMPTOM FRONT BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Blower motor driver circuit(s) shorted to ground - Blower motor driver circuit(s) shorted to voltage - Blower motor driver circuits shorted together - A/C - heater control module - speeds incorrect - Blower motor driver circuit(s) open - Blower motor resistor block - open speed HVAC System Test - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 509 Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 510 Test 5 Test 5 SYMPTOM HVAC SYSTEM TEST - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 511 POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active HVAC DTC's and system tests fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 512 Test 4 - 5 SYMPTOM REAR A/C - HEATER CONTROL ILLUMINATION INOPERATIVE - MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - Inoperative bulb - Ground circuit open - Rear blower rear control switch - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 513 Test 1 - 2 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 514 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 515 Test 11 - 14 SYMPTOM REAR BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #12 - Fused rear blower motor relay output circuit shorted to ground - Blower motor - Ground circuit open - A/C - heater control module - Check for power to rear blower motor - Blower motor - Rear blower high speed circuit open - Rear blower motor high circuit open - Rear blower motor resistor block - IPM - open circuit Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 516 - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Motor Speeds Incorrect - MTC Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 517 Test 3 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 518 Test 6 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 519 Test 10 SYMPTOM REAR BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to ground - A/C - heater control module - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to voltage - Rear blower motor front control feed circuit shorted to voltage - Rear blower driver CKT(s) shorted to rear blower front control feed CKT - Rear blower motor driver circuits shorted together - A/C - heater control module - Rear blower motor driver circuit(s) open - Rear blower motor resistor block Rear Blower Rear Control Switch INOP In One or More Speeds - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 520 Test 1 - 2 Test 3 SYMPTOM REAR BLOWER REAR CONTROL SWITCH INOP IN ONE OR MORE SPEEDS - MTC POSSIBLE CAUSES - Rear blower motor driver circuit(s) open - Rear blower rear control switch - Rear blower motor front control feed circuit open - A/C - heater control module Recirc Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 521 Test 1 - 2 Test 3 SYMPTOM RECIRC STATUS INDICATOR FLASHING - MTC TEST NOTE This symptom is diagnosed using the test A/C STATUS INDICATOR FLASHING - MTC. POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Any PCI Bus Indicator Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 522 Test 1 - 4 SYMPTOM ANY PCI BUS INDICATOR INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - No response - instrument cluster - No response - ECM / PCM - Indicator inoperative - Instrument cluster Seat Belt Indicator Always On Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 523 Test 1 SYMPTOM SEAT BELT INDICATOR ALWAYS ON POSSIBLE CAUSES - ACM seat belt indicator command present - Instrument cluster Overhead Console Test 1 - 4 SYMPTOM REPAIRING CMTC DISPLAYS DOUBLE DASH (- - ) IN TEMP DISPLAY POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 524 - No response - PCI BUS - powertrain control module - CMTC BUS message failure - Compass mini-trip computer - Ambient temperature sensor - PCM ambient air temperature sensor DTC present - CMTC internal Left Cylinder Lock Switch Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 525 Test 4 - 5 SYMPTOM LEFT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - left cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - left cylinder lock switch MUX short to voltage Remote Keyless Entry Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 526 Test 1 - 4 Test 5 - 6 SYMPTOM REMOTE KEYLESS ENTRY INOPERATIVE POSSIBLE CAUSES - DTC present - SKREEM DTC present - Test transmitter with tester - RKE transmitter inoperative - RKE transmitter not programmed - SKREEM module - RKE inoperative - SKREEM module - RKE inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 527 Right Cylinder Lock Switch Inoperative Test 1 - 3 Test 4 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 528 SYMPTOM RIGHT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - right cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - right cylinder lock switch MUX short to voltage Power Doors - Liftgate Test 1 - 4 SYMPTOM POWER LIFTGATE INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Power Doors - Sliding Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 529 Test 1 - 4 SYMPTOM POWER SLIDING DOOR INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Alarm Trips On Its Own Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 530 Test 1 - 4 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - Last VTSS cause - Attempt to trip alarm - Intermittent condition Left Front Door Does Not Trip VTSS Test 1 SYMPTOM LEFT FRONT DOOR DOES NOT TRIP VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 531 POSSIBLE CAUSES - Body control module - Check DRBIII(R) for driver door ajar response Left Sliding Door Does Not Trip VTSS Test 1 SYMPTOM LEFT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Monitor DRBIII(R) for left sliding door ajar status - Body control module Right Front Door Does Not Trip VTSS Test 1 SYMPTOM RIGHT FRONT DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for passenger door ajar response - Body control module Right Sliding Door Does Not Trip VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 532 Test 1 SYMPTOM RIGHT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for right rear door ajar response - Body control module VTSS Will Not Arm Test 1 - 3 SYMPTOM VTSS WILL NOT ARM POSSIBLE CAUSES - Check the VTSS status - Check for BCM DTC's and VTSS arming inhibitors - Check for PCI BUS communication of instrument cluster and SKIM - Body control module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 533 Body Control Module: Component Tests and General Diagnostics Six Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation Road Testing ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. WARNING: REASSEMBLE ALL COMPONENTS BEFORE ROAD TESTING A VEHICLE. DO NOT TRY TO READ THE DRBIII(R) SCREEN OR OTHER TEST EQUIPMENT DURING A TEST DRIVE. DO NOT HANG THE DRBIII(R) OR OTHER TEST EQUIPMENT FROM THE REARVIEW MIRROR DURING A TEST DRIVE. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIII(R) OR OTHER TEST EQUIPMENT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Vehicle Preparation For Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Glossary of Terms ABS antilock brake system ACT actuator APS adjustable pedals system ATC automatic temperature control BCM body control module BPS bladder pressure sensor BTS belt tension sensor CAB controller antilock brake CMTC compass/mini-trip computer CPA connector positive assurance DAB driver airbag DCHA diesel cabin heater assist (cabin heater) DLC data link connector DTC diagnostic trouble code DR driver EBL electric back lite (rear window defogger) ECM engine control module EVIC electronic vehicle information center FCM front control module GCC Gulf Coast Countries HE hall effect HFM hands free module HVAC heater ventilation, air conditioning IPM integrated power module KNB knee blocker airbag LDU lower drive unit LHD left hand drive MIC mechanical instrument cluster MTC manual temperature control MSMAPM memory seat/mirror/adjustable pedals module NAV navigation NGC next generation controller OBD on board diagnostics OCM occupant classification module OCS occupant classification system OCSVR occupant classification system verification required ODO odometer ORC occupant restraint controller PAB passenger airbag PASS passenger PCI Programmable Communication Interface (vehicle communication bus) PCM powertrain control module PDC power distribution center PLG power liftgate Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 534 PLGM power liftgate module PSD power sliding door PSDM power sliding door module PWM pulse width modulated RHD Right Hand Drive RKE remote keyless entry RX receive SAB seat airbag SBS seat belt switch SBT seat belt tensioner SKREEM sentry key remote entry module SQUIB also called initiator (located inside airbag) SRS supplemental restraint system TCM transmission control module TPMS tire pressure monitor system TX transmit VFD vacuum fluorescent display VTSS vehicle theft security system Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 535 Body Control Module: Testing and Inspection Diagnostic Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions Diagnostic Trouble Code Tests and Associated Procedures For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures Air Bag System Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Any Station Preset Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 536 Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 537 POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Test 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 538 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Pause/Play Switch Inoperative Test 1 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 539 Test 1 SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Remote Radio Controls Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 540 Test 4 - 7 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 541 Test 8 - 9 SYMPTOM REMOTE RADIO CONTROLS INOPERATIVE POSSIBLE CAUSES - Open radio control MUX circuit at the switch - Open radio control MUX return circuit at the switch - Remote radio switch - Body control module - internal short - Open clockspring - Open radio control MUX circuit - Open radio control MUX return circuit - Body control module - open internal Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 542 Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 543 POSSIBLE CAUSES - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure ATC Head LED(s)/Backlighting Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 544 Test 1 - 3 Test 4 - 5 SYMPTOM ATC HEAD LED(S)/BACK LIGHTING INOPERATIVE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 545 POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - ATC - LED(s) inoperative - ATC - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 546 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 547 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 548 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 549 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 550 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM FUSE #10 - Fused front blower motor relay output circuit shorted to ground - Blower motor shorted to ground - Front blower power module shorted to ground - Ground circuit open - Blower motor control circuit shorted to voltage - Blower motor control circuit open - Front blower power module open - Automatic temperature control module open - Check blower motor operation - Front blower power module open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 551 Test 1 Test 2 SYMPTOM FRONT BLOWER RUNS AT ONLY ONE SPEED Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 552 POSSIBLE CAUSES - Blower motor control circuit shorted to ground - Automatic temperature control module - Front blower power module HVAC System Test Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 553 Test 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 554 Test 6 Test 7 SYMPTOM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 555 HVAC SYSTEM TEST POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active ATC DTC's - Check for AC cooldown test fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear ATC Switch LED(s)/Backlighting Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 556 Test 4 - 5 SYMPTOM REAR ATC SWITCH LED(S)/BACK LIGHTING INOPERATIVE POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - Rear ATC switch - LED(s) inoperative - Rear ATC switch - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 557 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 558 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 559 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 560 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 561 Test 15 - 16 SYMPTOM REAR BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM Fuse #12 - Fused rear blower relay output circuit shorted to ground - Blower motor shorted to ground - Rear blower motor power module shorted to ground - Ground circuit open - Rear blower motor control circuit shorted to voltage - Rear blower motor control circuit open - Rear blower motor power module open - Automatic temperature control module open - Check blower motor operation - Rear blower motor power module open - IPM - open circuit - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 562 Test 1 Test 2 SYMPTOM REAR BLOWER RUNS AT ONLY ONE SPEED POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 563 - Rear blower motor control circuit shorted to ground - Automatic temperature control module - Rear blower motor power module Chime Inoperative Test 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE POSSIBLE CAUSES - Use DRB to actuate chime - Chime driver circuit - open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 564 - Chime driver circuit - short to ground - Chime driver circuit - short to voltage - Instrument cluster - BCM Key In Ignition and Drivers Door Open Chime Not Operating Properly Test 1 - 3 SYMPTOM KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME NOT OPERATING PROPERLY POSSIBLE CAUSES - DRB chime actuator - Driver door ajar status - Ignition switch - Body control module Vehicle Speed Warning Chime Problem Test 1 SYMPTOM PROBLEM WITH THE VEHICLE SPEED WARNING CHIME POSSIBLE CAUSES - Incorrect country code programmed in BCM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 565 - Body control module Left Front Door Ajar Switch Sense Circuit Open Test 1 - 4 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Left front door ajar switch ground circuit open - Left front door (lock motor) ajar switch - Left front door ajar switch sense circuit open - Body control module internal malfunction Left Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 566 Test 1 - 2 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left front door (lock motor) ajar switch shorted to ground - Left front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Left Sliding Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 567 Test 1 - 3 Test 4 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Left sliding door ajar switch sense circuit open - Left sliding door ajar switch sense circuit open - Body control module internal malfunction Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 568 - Left sliding door lock motor/ajar switch (latch assy). Left Sliding Door Ajar Switch Sense Circuit Shorted to Ground Test 1 - 3 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left sliding door lock motor/ajar switch shorted to ground - Left sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Left sliding door lock motor/ajar switch (latch assy). Liftgate Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 569 Test 1 - 4 SYMPTOM LIFTGATE AJAR CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Liftgate ajar switch ground circuit open - Liftgate ajar switch (cinch/release motor) - Liftgate ajar switch sense circuit open - Body control module internal malfunction Liftgate Ajar Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 570 Test 1 - 2 SYMPTOM LIFTGATE AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Liftgate ajar switch shorted to ground - Liftgate ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 571 Test 1 - 4 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Right front door ajar switch ground circuit open - Right front door (lock motor) ajar switch - Right front door ajar switch sense circuit open - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 572 Test 1 - 2 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right front door (lock motor) ajar switch shorted to ground - Right front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Sliding Door Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 573 Test 1 - 3 Test 4 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Right sliding door ajar switch sense circuit open - Right sliding door ajar switch sense circuit open - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 574 Right Sliding Door Ajar Circuit Shorted to Ground Test 1 - 3 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right sliding door lock motor/ajar switch shorted to ground - Right sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) A/C Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 575 Test 1 - 2 Test 3 SYMPTOM A/C STATUS INDICATOR FLASHING - MTC POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Blend/Mode/Recirc Door Operation Improper -- Dual & Three-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 576 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 577 Test 4 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 578 Test 7 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 579 Test 10 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER -- DUAL & THREE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Passenger blend door actuator/linkage/door - Driver blend door actuator/linkage/door - Recirculation door actuator/linkage/door - Rear mode door actuator/linkage/door - Rear blend door actuator/linkage/door Blend/Mode/Recirc Door Operation Improper --Single-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 580 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 581 Test 4 - 7 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER --SINGLE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Blend door actuator/linkage/door - Recirculation door actuator/linkage/door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 582 Front A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Test 4 SYMPTOM FRONT A/C - HEATER CONTROL ILLUMINATION INOPERATIVE -MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - A/C - heater control module - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 583 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 584 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 585 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 586 Test 11 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 587 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #10 - Fused front blower motor relay output circuit shorted to ground - Front blower motor resistor block shorted to ground - Front blower motor resistor block shorted to ground - Blower motor - Blower motor - A/C - heater control module - Ground circuit open - Blower motor high driver circuit open - Front blower motor resistor block open - Front blower motor resistor block open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Motor Speeds Incorrect - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 588 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 589 Test 3 - 5 SYMPTOM FRONT BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Blower motor driver circuit(s) shorted to ground - Blower motor driver circuit(s) shorted to voltage - Blower motor driver circuits shorted together - A/C - heater control module - speeds incorrect - Blower motor driver circuit(s) open - Blower motor resistor block - open speed HVAC System Test - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 590 Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 591 Test 5 Test 5 SYMPTOM HVAC SYSTEM TEST - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 592 POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active HVAC DTC's and system tests fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 593 Test 4 - 5 SYMPTOM REAR A/C - HEATER CONTROL ILLUMINATION INOPERATIVE - MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - Inoperative bulb - Ground circuit open - Rear blower rear control switch - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 594 Test 1 - 2 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 595 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 596 Test 11 - 14 SYMPTOM REAR BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #12 - Fused rear blower motor relay output circuit shorted to ground - Blower motor - Ground circuit open - A/C - heater control module - Check for power to rear blower motor - Blower motor - Rear blower high speed circuit open - Rear blower motor high circuit open - Rear blower motor resistor block - IPM - open circuit Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 597 - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Motor Speeds Incorrect - MTC Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 598 Test 3 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 599 Test 6 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 600 Test 10 SYMPTOM REAR BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to ground - A/C - heater control module - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to voltage - Rear blower motor front control feed circuit shorted to voltage - Rear blower driver CKT(s) shorted to rear blower front control feed CKT - Rear blower motor driver circuits shorted together - A/C - heater control module - Rear blower motor driver circuit(s) open - Rear blower motor resistor block Rear Blower Rear Control Switch INOP In One or More Speeds - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 601 Test 1 - 2 Test 3 SYMPTOM REAR BLOWER REAR CONTROL SWITCH INOP IN ONE OR MORE SPEEDS - MTC POSSIBLE CAUSES - Rear blower motor driver circuit(s) open - Rear blower rear control switch - Rear blower motor front control feed circuit open - A/C - heater control module Recirc Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 602 Test 1 - 2 Test 3 SYMPTOM RECIRC STATUS INDICATOR FLASHING - MTC TEST NOTE This symptom is diagnosed using the test A/C STATUS INDICATOR FLASHING - MTC. POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Any PCI Bus Indicator Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 603 Test 1 - 4 SYMPTOM ANY PCI BUS INDICATOR INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - No response - instrument cluster - No response - ECM / PCM - Indicator inoperative - Instrument cluster Seat Belt Indicator Always On Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 604 Test 1 SYMPTOM SEAT BELT INDICATOR ALWAYS ON POSSIBLE CAUSES - ACM seat belt indicator command present - Instrument cluster Overhead Console Test 1 - 4 SYMPTOM REPAIRING CMTC DISPLAYS DOUBLE DASH (- - ) IN TEMP DISPLAY POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 605 - No response - PCI BUS - powertrain control module - CMTC BUS message failure - Compass mini-trip computer - Ambient temperature sensor - PCM ambient air temperature sensor DTC present - CMTC internal Left Cylinder Lock Switch Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 606 Test 4 - 5 SYMPTOM LEFT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - left cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - left cylinder lock switch MUX short to voltage Remote Keyless Entry Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 607 Test 1 - 4 Test 5 - 6 SYMPTOM REMOTE KEYLESS ENTRY INOPERATIVE POSSIBLE CAUSES - DTC present - SKREEM DTC present - Test transmitter with tester - RKE transmitter inoperative - RKE transmitter not programmed - SKREEM module - RKE inoperative - SKREEM module - RKE inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 608 Right Cylinder Lock Switch Inoperative Test 1 - 3 Test 4 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 609 SYMPTOM RIGHT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - right cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - right cylinder lock switch MUX short to voltage Power Doors - Liftgate Test 1 - 4 SYMPTOM POWER LIFTGATE INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Power Doors - Sliding Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 610 Test 1 - 4 SYMPTOM POWER SLIDING DOOR INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Alarm Trips On Its Own Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 611 Test 1 - 4 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - Last VTSS cause - Attempt to trip alarm - Intermittent condition Left Front Door Does Not Trip VTSS Test 1 SYMPTOM LEFT FRONT DOOR DOES NOT TRIP VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 612 POSSIBLE CAUSES - Body control module - Check DRBIII(R) for driver door ajar response Left Sliding Door Does Not Trip VTSS Test 1 SYMPTOM LEFT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Monitor DRBIII(R) for left sliding door ajar status - Body control module Right Front Door Does Not Trip VTSS Test 1 SYMPTOM RIGHT FRONT DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for passenger door ajar response - Body control module Right Sliding Door Does Not Trip VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 613 Test 1 SYMPTOM RIGHT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for right rear door ajar response - Body control module VTSS Will Not Arm Test 1 - 3 SYMPTOM VTSS WILL NOT ARM POSSIBLE CAUSES - Check the VTSS status - Check for BCM DTC's and VTSS arming inhibitors - Check for PCI BUS communication of instrument cluster and SKIM - Body control module Six Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 614 - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation Road Testing ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. WARNING: REASSEMBLE ALL COMPONENTS BEFORE ROAD TESTING A VEHICLE. DO NOT TRY TO READ THE DRBIII(R) SCREEN OR OTHER TEST EQUIPMENT DURING A TEST DRIVE. DO NOT HANG THE DRBIII(R) OR OTHER TEST EQUIPMENT FROM THE REARVIEW MIRROR DURING A TEST DRIVE. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIII(R) OR OTHER TEST EQUIPMENT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Vehicle Preparation For Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Glossary of Terms ABS antilock brake system ACT actuator APS adjustable pedals system ATC automatic temperature control BCM body control module BPS bladder pressure sensor BTS belt tension sensor CAB controller antilock brake CMTC compass/mini-trip computer CPA connector positive assurance DAB driver airbag DCHA diesel cabin heater assist (cabin heater) DLC data link connector DTC diagnostic trouble code DR driver EBL electric back lite (rear window defogger) ECM engine control module EVIC electronic vehicle information center FCM front control module GCC Gulf Coast Countries HE hall effect HFM hands free module HVAC heater ventilation, air conditioning IPM integrated power module KNB knee blocker airbag LDU lower drive unit LHD left hand drive MIC mechanical instrument cluster MTC manual temperature control MSMAPM memory seat/mirror/adjustable pedals module NAV navigation NGC next generation controller OBD on board diagnostics OCM occupant classification module OCS occupant classification system OCSVR occupant classification system verification required ODO odometer ORC occupant restraint controller PAB passenger airbag PASS passenger PCI Programmable Communication Interface (vehicle communication bus) PCM powertrain control module PDC power distribution center PLG power liftgate PLGM power liftgate module PSD power sliding door PSDM power sliding door module PWM pulse width modulated RHD Right Hand Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 615 RKE remote keyless entry RX receive SAB seat airbag SBS seat belt switch SBT seat belt tensioner SKREEM sentry key remote entry module SQUIB also called initiator (located inside airbag) SRS supplemental restraint system TCM transmission control module TPMS tire pressure monitor system TX transmit VFD vacuum fluorescent display VTSS vehicle theft security system DRB III Error Messages and Blank Screen DRBIII(R) ERROR MESSAGES Under normal operation, the DRBIII(R) will display one of only two error messages: user-requested WARM Boot or User-Requested COLD Boot. If the DRBIII(R) should display any other error message, record the entire display and call the STAR Center. This is a sample of such an error message display: ver:2.14 date: 26 Jul93 file: key_iff.cc date: Jul26 1993 line: 548 err: 0xi User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRBIII(R) DOES NOT POWER UP (BLANK SCREEN) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRBIII(R). Check for proper grounds at DLC cavities 4 and 5. If all connections are proper between the DRBIII(R) and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRBIII(R) may be the result or a faulty cable or vehicle wiring. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. DRB III Safety Information WARNING: EXCEEDING THE LIMITS OF THE DRBIII(R) MULTIMETER IS DANGEROUS. READ ALL DRBIII(R) INSTRUCTIONS BEFORE USING THE MULTIMETER. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 616 - Follow the vehicle manufacturer s service specifications at all times. - Do not use the DRBIII(R) if it has been damaged. - Do not use the test leads if the insulation is damaged or if metal is exposed. - To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. - Choose the proper range and functions for the measurement. Do not try voltage or current measurement that may exceed the rated capacity. - Do not exceed the limits shown in the table below: *Ohms cannot be measured if voltage is present. Ohms can be measured only in a non-powered circuit. - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10 A. - When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. - When measuring current, connect the meter in series with the load. - Disconnect the live test lead before disconnecting the common test lead. - When using the meter function, keep the DRBIII(R) away from spark plug or coil wires to avoid measuring error from outside interference. KDB Lab Scope Pattern Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 617 PCI Bus Lab Scope Pattern Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 618 Body Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lower instrument panel silencer. 3. Remove the knee blocker and reinforcement. 4. Disconnect the five wire connectors from the bottom of the Body Control Module (BCM). 5. Move bulkhead wiring aside. 6. Remove the screws holding the BCM to the bulkhead. 7. Remove the BCM from the mounting bracket. INSTALLATION 1. Install the BCM to the mounting bracket. 2. Install the screws holding the BCM to the bulkhead. 3. Connect the five wire connectors to the bottom of the Body Control Module (BCM). 4. Install the knee blocker and reinforcement. 5. Install the lower instrument panel silencer. 6. Connect the battery negative cable. 7. Verify proper operation of BCM and its functions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 619 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRBIII(R) (diagnostic read-out box) Jumper wires Ohmmeter Voltmeter Sentry Key Tester Test Light 8443 SRS Airbag System Load Tool 9077 Occupant Classification Seat Weights Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs Engine Control Module: Technical Service Bulletins Engine Controls - Programming Generic PCMs NUMBER: 18-029-07 GROUP: Vehicle Performance DATE: April 26, 2007 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-006-04 REV. B, DATED SEPTEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A MINOR REVISION AND **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT UPDATED PL PARTS APPLICATIONS. SUBJECT: Generic Powertrain Control Module (PCM) Procedure OVERVIEW: This bulletin involves programming a generic PCM with software. MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR) Ram Truck 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004-2005 (KJ) Liberty 2004 - 2005 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2004-2005 (PL) Neon 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2005 (TJ) Wrangler Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 624 NOTE: Refer to the table for specific applications. DISCUSSION: Mopar(R) is currently phasing out pre-programmed PCMs for the vehicles listed. New modules will no longer be pre-programmed when received from Mopar(R). Replacement of future PCMs will require programming utilizing the DRBIII(R) and TechCONNECT. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 625 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 626 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 627 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 628 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 629 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: When flashing a 2002 - 2004 LH vehicle the BCM may need to be disconnected if experiencing failures during the flash of the transmission portion of the PCM. The BCM will need to be disconnected after the module ID portion of the flash is complete. Before pressing Page Forward to begin the flash of the PCM Turn the Key to the OFF position and disconnect the BCM. Then turn the KEY to the RUN position and Press Page Forward to begin the PCM flash session. NOTE: If vehicle is a DAKOTA, then the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for any erroneous DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRB III(R) reboots to the MAIN MENU, proceed to Step 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 630 NOTE: If your vehicle is a 2002 LH and the original PCM part number begins with 04 the technician should use the 2002 LH Part Number Reference chart above to determine the corresponding "NEW" part number. This new number from the chart should then be entered into the Tech tools application as the original part number. If the original PCM number begins with 05 no change to the flash selection process is required. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the first ten (10) characters of the "PCM part # " on the repair order for later reference. NOTE: If the PCM is not operational, the part number can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step. 3. Page back to the "Main Menu" 4. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. 5. If the vehicle is not equipped with SKIM then proceed to step 6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with step 6. This information is available from one of the following: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. CAUTION: Failure to install the SKIM pin number into the module after flashing the PCM will cause a start and stall condition. 6. Replace the PCM using the appropriate generic control module. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E, Electronic Control Modules, Powertrain Control Module, Removal/Installation. 7. Open the hood, install a battery charger and verify battery state is above 11.5 volts. 8. If the old "PCM part # " is known, proceed to step 14. If the old "PCM part # " is not known, proceed to next step. 9. On DealerCONNECT select the "Service" tab. 10. Select "Vehicle Information Plus". 11. Manually enter the VIN and mileage and select "Enter". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 631 12. Select the "Vehicle Option" tab. 13. Under the "Vehicle Option window, identify and record: a. Engine. b. Emissions (Federal or California). c. Transmission (Automatic, 5-speed manual, etc.). 14. Connect the DRBIII(R) to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 15. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates. NOTE: Do NOT enter the generic controller part number in step 16a below. 16. Determine the proper calibration: a. If the old "PCM part # " is known, enter the part number of the old controller in the "Parts Criteria p/n window. Proceed to step 16. b. If the old "PCM part # " is not known, select the correct calibration based on the information that was recorded from "Vehicle Options" in step 13. 17. Select the correct calibration. 18. Select the "Download/Update button. 19. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII(R). When the flash process is completed, proceed to next step. 20. Enter the VIN in the PCM. Using the DRBIII® select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "Engine" e. "Miscellaneous" f. "Check VIN" g. If the vehicle is not equipped with SKIM proceed to step 20h. If the vehicle is equipped with SKIM follow the directions on the DRBIII(R). When the VIN and SKIM key has been programmed, proceed to step 20. h. Enter the VIN as requested by the DRBIII(R). 21. Update the PCM mileage. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Check PCM Odometer" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 632 g. "NO" h. Enter the current odometer mileage and then press "Enter". i. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter". 22. Proceed as follows: a. If the vehicle is equipped with an automatic transmission, proceed to step 24. b. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 24. c. If the vehicle is equipped with a Turbo engine and manual transmission, proceed to step 23. 23. On vehicles equipped with a Turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII® Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Pinion Factor" g. Select the correct tire size and then select "Page Back" to exit. h. Proceed to step 24. 24. On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Transmission" e. "Transmission Module" f. "Miscellaneous" g. "Pinion Factor" h. Select the correct tire size and then select "Page Back" to exit. i. Enter "Quick Learn" and then follow the instructions on the DRBIII(R). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 633 25. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 634 Engine Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 635 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 636 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 637 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 638 Engine Control Module: Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views Powertrain Control Module C1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 641 Powertrain Control Module C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 642 Powertrain Control Module C3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 643 Powertrain Control Module C4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 644 Engine Control Module: Description and Operation Powertrain Control Module (PCM) The Powertrain Control Module (PCM) is a digital computer containing a microprocessor. The PCM receives input signals from various switches and sensors referred to as Powertrain Control Module Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices referred to as Powertrain Control Module Outputs. NOTE: PCM Inputs: - Air Conditioning Pressure Transducer - Ambient temperature Sensor - ASD Relay - Battery Temperature Sensor (NGC) - Battery Voltage - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Distance Sensor (from transmission control module) - EGR Position Feedback - Engine Coolant Temperature Sensor - Heated Oxygen Sensors - Ignition sense - Intake Air Temperature Sensor - Knock Sensor - Leak Detection Pump Feedback - Manifold Absolute Pressure (MAP) Sensor - Park/Neutral - PCI Bus - Power Steering Pressure Switch - Proportional Purge Sense - SCI Receive - Speed Control - Throttle Position Sensor - Transmission Control Relay (Switched B+) - Transmission Pressure Switches - Transmission Temperature Sensor - Transmission Input Shaft Speed Sensor - Transmission Output Shaft Speed Sensor - Transaxle Gear Engagement Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 645 - Vehicle Speed NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Automatic Shut Down (ASD) and Fuel Pump Relays - Data Link Connector (PCI and SCI Transmit) - Double Start Override - EGR Solenoid - Fuel Injectors - Generator Field - High Speed Fan Relay - Idle Air Control Motor - Ignition Coils - Leak Detection Pump - Low Speed Fan Relay - MTV Actuator - Proportional Purge Solenoid - SRV Valve - Speed Control Relay - Speed Control Vent Relay - Speed Control Vacuum Relay - 8 Volt Output - 5 Volt Output - Torque Reduction Request - Transmission Control Relay - Transmission Solenoids - Vehicle Speed Based on inputs it receives, the powertrain control module (PCM) adjusts fuel injector pulse width, idle speed, ignition timing, and canister purge operation. The PCM regulates the cooling fans, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the generator field. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. - Battery Voltage - Intake Air Temperature Sensor - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Exhaust Gas Oxygen Content (heated oxygen sensors) - Manifold Absolute Pressure - Throttle Position The PCM adjusts engine idle speed through the idle air control motor based on the following inputs. - Brake Switch - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Park/Neutral - Transaxle Gear Engagement - Throttle Position - Vehicle Speed The PCM adjusts ignition timing based on the following inputs. - Intake Air Temperature - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Knock Sensor - Manifold Absolute Pressure - Park/Neutral - Transaxle Gear Engagement - Throttle Position The automatic shut down (ASD) and fuel pump relays are mounted externally, but turned on and off by the powertrain control module through the same circuit. The camshaft and crankshaft signals are sent to the powertrain control module. If the PCM does not receive both signals within approximately one second of engine cranking, it deactivates the ASD and fuel pump relays. When these relays are deactivated, power is shut off to the fuel injectors, ignition coils, fuel pump and the heating element in each oxygen sensor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 646 The PCM contains a voltage converter that changes battery voltage to a regulated 8.0 volts. The 8.0 volts power the camshaft position sensor, crankshaft position sensor and vehicle speed sensor. The PCM also provides a 5.0 volts supply for the engine coolant temperature sensor, intake air temperature sensor, manifold absolute pressure sensor and throttle position sensor. The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage in new PCM. Use the DRBIII(R) scan tool to change the mileage in the PCM. TRANSMISSION CONTROL CLUTCH VOLUME INDEX (CVI) Example Of CVI Calculation An important function of the PCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The PCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the PCM that represents input shaft rpm. The Output Speed Sensor provides the PCM with output shaft speed information. By comparing the two inputs, the PCM can determine transaxle gear ratio. This is important to the CVI calculation because the PCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the PCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the PCM can determine the volume of fluid used to apply or release a friction element. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 647 The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: SHIFT SCHEDULES As mentioned earlier, the PCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Part 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 648 Part 2 As driving conditions change, the PCM appropriately adjusts the shift schedule. Refer to the chart to determine the appropriate operation expected, depending on driving conditions. SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). DATA BUS COMMUNICATION RECEIVE - PCM INPUT The PCM uses the SCI communication bus to preform engine diagnostics and flash operations. The transmission side of the PCM uses the SCI communication bus to flash new software. However, diagnostics is performed via the vehicles J1850 bus for the transmission side of the PCM. IGNITION SENSE - PCM INPUT The ignition sense input informs the Powertrain Control Module (PCM) that the ignition switch is in the crank or run position. PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded separately from the ground pins. 5 VOLT SUPPLY - PCM OUTPUT The PCM supplies 5 volts to the following sensors: - A/C pressure transducer - Ambient Temperature sensor - Battery temperature - Camshaft Position Sensor (NGC) - Crankshaft Position Sensor (NGC) - Engine coolant temperature sensor - Inlet Air Temperature Sensor - Knock sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 649 - Linear EGR solenoid (if equipped) - Manifold absolute pressure sensor - Oil Pressure Switch - Throttle position sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming Engine Control Module: Service and Repair PCM/SKIM Programming NOTE: Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. When a PCM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new PCM. 2. Program the new SKIM. 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE PCM The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the scan tool. Perform the following steps to program the secret key into the PCM. 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Enter secured access mode by entering the vehicle four-digit PIN. 5. Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 6. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). 7. Press Page Back to get to the Select System menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK. 8. The scan tool will ask, Is odometer reading between XX and XX? Select the YES or NO button on the scan tool. If NO is selected, the scan tool will read, Enter odometer Reading. Enter the odometer reading from the Instrument Panel and press ENTER. PROGRAMMING THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Program the vehicle four-digit PIN into SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. 6. Select YES to update VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the secret key (the PCM will send the secret key to the SKIM). 8. Program ignition keys to SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEY'S. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following messages: Programming Not Attempted The scan tool attempts to read the programmed key status and there are no keys programmed into SKIM memory. Programming Key Failed (Possible Used Key From Wrong Vehicle) SKIM is unable to program key due to one of the following: - faulty ignition key transponder - ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming > Page 652 - SKIM transponder ID memory is full. 5. Obtain ignition keys to be programmed from customer (8 keys maximum). 6. Using the scan tool, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN. KEYS. 7. Program all ignition keys. Learned Key In Ignition Ignition key transponder ID is currently programmed in SKIM memory. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming > Page 653 Engine Control Module: Service and Repair Powertrain Control Module SBEC Controller REMOVAL 1. Disconnect the negative battery cable. 2. Remove the battery shield. PCM 3. Remove the 2 upper PCM bracket bolts. 4. Remove the 2 PCM connectors. 5. Remove the headlamp PCM Lower Bolt 6. Remove the lower PCM mounting bolt. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming > Page 654 7. Remove PCM. INSTALLATION 1. Install the PCM. 2. Install the lower PCM mounting bolt. Tighten bolt. 3. Install the 2 upper PCM bracket bolts. Tighten bolt. 4. Install the headlamp. 5. Install the 2 PCM connectors. 6. Install the battery shield. 7. Connect the negative battery cable. NGC Controller REMOVAL NGC Controller Location The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage and vehicle identification number (VIN) in the new PCM. Use the DRBIII(R) scan tool to change the millage and VIN in the PCM. If this step is not done a Diagnostic Trouble Code (DTC) may be set. 1. Turn wheels to the left. 2. Disconnect the negative battery cable. 3. Raise vehicle and support. Splash Shield Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming > Page 655 4. Remove the left front wheel well splash shield. NGC Controller 5. Unlock and disconnect the electrical connectors. 6. Remove 3 screws from PCM to mounting bracket. 7. Remove the PCM. INSTALLATION The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage and vehicle identification number (VIN) in the new PCM. Use the DRBIII(R) scan tool to change the millage and VIN in the PCM. If this step is not done a diagnostic trouble code (DTC) may be set and SKIM must be done or car will not start if it is a SKIM equipped car. If a SKIM car you must do a secret key transfer also. 1. Install PCM module to the mounting bracket. 2. Install electrical connectors and lock. 3. Install the splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. 6. Using DRBIII(R) scan tool, program mileage and vehicle identification number (VIN) into PCM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 659 Main Relay (Computer/Fuel System): Diagrams Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 660 Auto Shut Down Relay Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 661 Main Relay (Computer/Fuel System): Description and Operation AUTO SHUT DOWN RELAY The relay is located in the Power Distribution Center (PDC). For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary The engine switched battery (NGC vehicles) informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is also used to power certain drivers on NGC vehicles. When energized, the ASD relay on NGC vehicles provides power to operate the injectors, ignition coil, generator field, O2 sensor heaters (both upstream and downstream), evaporative purge solenoid, EGR solenoid (if equipped) wastegate solenoid (if equipped), and NVLD solenoid (if equipped). The ASD relay also provides a sense circuit to the PCM for diagnostic purposes. If the PCM does not receive 12 volts from this input after grounding the control side of the ASD relay, it sets a Diagnostic Trouble Code (DTC). The PCM energizes the ASD any time there is an engine speed that exceeds a predetermined value (typically about 50 rpm). The ASD relay can also be energized after the engine has been turned off to perform an O2 sensor heater test, if vehicle is equipped with OBD II diagnostics. As mentioned earlier, the PCM energizes the ASD relay during an O2 sensor heater test. On NGC vehicles it checks the O2 heater upon vehicle start. The PCM still operates internally to perform several checks, including monitoring the O2 sensor heaters. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 666 Fuel Pump Relay: Description and Operation The fuel pump relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. The fuel pump relay supplies battery voltage to the fuel pump. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuel pump relay power circuit contains a fuse between the buss bar in the PDC and the relay. The fuse is located in the PDC. Refer to the Wiring Diagrams for circuit information. The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position. When the ignition switch is in the On position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 670 Main Relay (Computer/Fuel System): Diagrams Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 671 Auto Shut Down Relay Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 672 Main Relay (Computer/Fuel System): Description and Operation AUTO SHUT DOWN RELAY The relay is located in the Power Distribution Center (PDC). For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary The engine switched battery (NGC vehicles) informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is also used to power certain drivers on NGC vehicles. When energized, the ASD relay on NGC vehicles provides power to operate the injectors, ignition coil, generator field, O2 sensor heaters (both upstream and downstream), evaporative purge solenoid, EGR solenoid (if equipped) wastegate solenoid (if equipped), and NVLD solenoid (if equipped). The ASD relay also provides a sense circuit to the PCM for diagnostic purposes. If the PCM does not receive 12 volts from this input after grounding the control side of the ASD relay, it sets a Diagnostic Trouble Code (DTC). The PCM energizes the ASD any time there is an engine speed that exceeds a predetermined value (typically about 50 rpm). The ASD relay can also be energized after the engine has been turned off to perform an O2 sensor heater test, if vehicle is equipped with OBD II diagnostics. As mentioned earlier, the PCM energizes the ASD relay during an O2 sensor heater test. On NGC vehicles it checks the O2 heater upon vehicle start. The PCM still operates internally to perform several checks, including monitoring the O2 sensor heaters. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Shut Down Relay (For Antitheft) > Component Information > Description and Operation Ignition Shut Down Relay (For Antitheft): Description and Operation AUTO SHUT DOWN RELAY The relay is located in the Power Distribution Center (PDC). For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary The engine switched battery (NGC vehicles) informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is also used to power certain drivers on NGC vehicles. When energized, the ASD relay on NGC vehicles provides power to operate the injectors, ignition coil, generator field, O2 sensor heaters (both upstream and downstream), evaporative purge solenoid, EGR solenoid (if equipped) wastegate solenoid (if equipped), and NVLD solenoid (if equipped). The ASD relay also provides a sense circuit to the PCM for diagnostic purposes. If the PCM does not receive 12 volts from this input after grounding the control side of the ASD relay, it sets a Diagnostic Trouble Code (DTC). The PCM energizes the ASD any time there is an engine speed that exceeds a predetermined value (typically about 50 rpm). The ASD relay can also be energized after the engine has been turned off to perform an O2 sensor heater test, if vehicle is equipped with OBD II diagnostics. As mentioned earlier, the PCM energizes the ASD relay during an O2 sensor heater test. On NGC vehicles it checks the O2 heater upon vehicle start. The PCM still operates internally to perform several checks, including monitoring the O2 sensor heaters. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 681 Air Bag Control Module: Diagrams Occupant Restraint Controller C1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 682 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 683 Occupant Restraint Controller C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 684 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 685 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 686 Air Bag Control Module: Description and Operation Occupant Restraint Controller - Typical The Occupant Restraint Controller (ORC) is also sometimes referred to as the Airbag Control Module (ACM). ORC Location The ORC is secured with screws to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel just behind and underneath the instrument panel center stack in the passenger compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with four screws to enclose and protect the internal electronic circuitry and components. An arrow printed on the label on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has integral mounting flanges, the ORC has two molded plastic electrical connectors that exits the right facing side of the ORC housing. These terminal pins connect the ORC to the vehicle electrical system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 687 The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for vehicles with or without curtain airbags. The ORC cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The microprocessor in the Occupant Restraint Controller (ORC) contains the supplemental restraint system logic circuits and controls all of the supplemental restraint system components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Programmable Communication Interface (PCI) data bus. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and for supplemental restraint system diagnosis and testing through the 16-way Data Link Connector (DLC) located on the driver side lower edge of the instrument panel. The ORC microprocessor continuously monitors all of the supplemental restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the PCI data bus to turn on the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTC's, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. On models equipped with the Occupant Classification System (OCS), the ORC communicates with the Occupant Classification Module (OCM) over the PCI data bus. The ORC will internally disable the passenger airbag and seat belt tensioner deployment circuits if the OCM detects that the passenger side front seat is unoccupied or that it is occupied by a load that is inappropriate for an airbag deployment. The ORC also provides a control output to the Passenger Airbag Disabled (PAD) indicator through the passenger airbag indicator driver circuit. The OCM notifies the ORC when it has detected a monitored system fault and stored a DTC in its memory for any faulty OCS component or circuit, then the ORC sets a DTC and controls the airbag indicator operation accordingly. The ORC receives battery current through two circuits; a fused ignition switch output (RUN) circuit through a fuse in the Junction Block (JB), and a fused ignition switch output (RUN/START) circuit through a second fuse in the JB. The ORC receives ground through a ground circuit of the instrument panel wire harness. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the front supplemental restraint components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup supplemental restraint system protection in case there is a loss of battery current supply to the ORC during an impact. Two sensors are contained within the ORC, an electronic impact sensor and a safing sensor. The ORC also monitors inputs from eight remote impact sensors. Two front impact sensors are located on each outboard side of the lower radiator support, and three side impact sensors are located on each side of the vehicle at the B-pillar, in the lower sliding door opening in front of the C-pillar, and over the rear wheel well between the C and D-pillars. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The safing sensor is an electronic accelerometer sensor within the ORC that provides an additional logic input to the ORC microprocessor. The safing sensor is used to verify the need for a supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with curtain airbags, there is a second safing sensor within the ORC to provide confirmation to the ORC microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require supplemental restraint system protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either curtain airbag. For vehicles equipped with the OCS, the passenger front airbag and seat belt tensioner will be deployed by the ORC only if enabled by the OCM messages (PAD indicator OFF) at the time of the impact. To diagnose and test the ORC and all airbag system components, use a scan tool and the appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 688 Air Bag Control Module: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS), NEVER REPLACE BOTH THE OCCUPANT RESTRAINT CONTROLLER (ORC) AND THE OCCUPANT CLASSIFICATION MODULE (OCM) AT THE SAME TIME. IF BOTH REQUIRE REPLACEMENT, REPLACE THE OCM FIRST. THEN PERFORM THE AIRBAG SYSTEM TEST INCLUDING AN IGNITION-ON TIME OF AT LEAST ONE MINUTE BEFORE REPLACING THE ORC. BOTH THE ORC AND THE OCM STORE OCS CALIBRATION DATA, WHICH THEY TRANSFER TO ONE ANOTHER DURING THE FIRST MINUTE OF IGNITION-ON TIME AFTER ONE OF THEM IS REPLACED. IF BOTH MODULES ARE REPLACED AT THE SAME TIME, AN IRREVERSIBLE FAULT WILL BE SET IN BOTH MODULES. 1. Disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG SYSTEM OR COMPONENT SERVICE. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, PERSONAL INJURY OR DEATH. 2. Remove storage bin from instrument panel. ORC - Remove/Install 3. Remove three bolts holding ORC to floor bracket. 4. Disconnect the wire connectors from the ORC. 5. Remove the ORC from vehicle. INSTALLATION WARNING: - DO NOT INSTALL ORC IF MOUNTING LOCATION IS DEFORMED OR DAMAGED. THIS WILL CAUSE THE ORC TO BE IMPROPERLY LOCATED AND COULD RESULT IN OCCUPANT PERSONAL INJURY OR DEATH. - USE CORRECT SCREWS WHEN INSTALLING THE ORC. - NEVER REPLACE BOTH THE OCCUPANT RESTRAINT CONTROLLER (ORC) AND THE OCCUPANT CLASSIFICATION MODULE (OCM) AT THE SAME TIME. IF BOTH REQUIRE REPLACEMENT, REPLACE ONE, THEN PERFORM THE AIRBAG SYSTEM TEST BEFORE REPLACING THE OTHER. BOTH THE ORC AND THE OCM STORE OCCUPANT CLASSIFICATION SYSTEM (OCS) CALIBRATION DATA, WHICH THEY TRANSFER TO ONE ANOTHER WHEN ONE OF THEM IS REPLACED. IF BOTH ARE REPLACED AT THE SAME TIME, AN IRREVERSIBLE FAULT WILL BE SET IN BOTH MODULES AND THE OCS MAY MALFUNCTION AND RESULT IN PERSONAL INJURY OR DEATH. 1. Install the ORC into vehicle. 2. Connect the wire connector to the ORC. 3. Install three bolts holding ORC to floor bracket. Torque bolts to 7.3 - 9.6 Nm (65 to 85 in. lbs.) 4. Install the storage bin onto the instrument panel. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 689 SYSTEM TEST IS NOT PERFORMED FIRST. 5. Verify vehicle and system operation. 6. Close hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 694 Starter Relay: Diagrams 8w-10-3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 695 8w-10-5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 696 Starter Motor Relay Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations Control Module: Locations Control Module Locations NGC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 702 Control Module: Description and Operation Fig.14 Transmission Control Module (TCM) Location The Transmission Control Module (TCM) is located behind the left fender and is fastened with three screws to three clips in the left frame rail forward of the suspension (Fig. 14). The TCM is the controlling unit for all electronic operations of the transaxle. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transaxle. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the J1850 communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor (CKP) - Transmission Range Sensor (TRS) - Pressure Switches (L/R, 2/4, OD) - Transmission Temperature Sensor (Integral to TRS) - Input Shaft Speed Sensor - Output Shaft Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Speed Control ON/OFF Switch - Engine Coolant Temperature - Ambient/Battery Temperature - Brake Switch Status - DRB Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids (LR/CC, 2/4, OD and UD) - Vehicle Speed (to PCM) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 703 - Torque Reduction Request (to PCM) An example of a TCM indirect output is: - Transmission Temperature (to PCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indices (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB scan tool) Clutch Volume Index (CVI) An important function of the TCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.15 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transaxle gear ratio. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 15). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 704 Clutch Volumes Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 705 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 706 Control Module: Service and Repair ELECTRONIC PINION FACTOR (IF APPLICABLE) NOTE: After replacing the EATX/PCM, you must reprogram pinion factor. In some vehicle applications, the pinion factor is a fixed value and cannot be changed or updated. The transmission output speed signal supplies distance pulses to the control module, which are used to calculate speed and mileage. A pinion factor is stored in the control module in order to provide the appropriate distance pulses for other vehicle systems. The pinion factor is programmed into the control module at the assembly plant. The pinion factor must be set when replacing the control module. If the pinion factor is not set or incorrectly set, any speed related functions will not operate correctly i.e. speedometer, speed control, rolling door locks, other control modules will be affected that depend on speed information. Using the following steps, the pinion factor can be checked and/or reset using the DRBIII: 1. Select Transmission system, then Miscellaneous functions, then Pinion Factor. The DRBIII will display the current tire size. 2. If the tire size is incorrect, press the Enter key and then select the correct size. 3. Press the Page Back key to exit the reset procedure. Notes About Electronic Pinion Factor Features The nature of the electronic pinion factor requires that certain features must be taken into consideration. ^ If no pinion factor is stored in an installed control module, the vehicle speedometer will not operate, engine speed will be limited to 2300 RPM, and catalyst damage may occur. ^ Selecting a wrong tire size will cause the speedometer to be inaccurate and will also cause any speed related features to operate improperly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 710 Transmission Control System Relay: Diagrams Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 711 Transmission Control Relay (EATX) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Transmission Control System Relay: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION CONTROL RELAY - DESCRIPTION The transmission control relay (Fig. 336) is located in the Intelligent Power Module (IPM), which is located on the left side of the engine compartment between the battery and left fender. OPERATION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 714 Transmission Control System Relay: Description and Operation 40TE Automatic Transaxle TRANSMISSION CONTROL RELAY DESCRIPTION The transmission control relay (Fig. 302) is located in the Intelligent Power Module (IPM), which is located on the left side of the engine compartment between the battery and left fender. OPERATION The Transmission Control Relay is supplied fused B+ voltage, energized by the PCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the PCM energizes the relay. Prior to this, the PCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the PCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 719 Rear Defogger Relay: Description and Operation Rear Window Defogger (EBL) Relay The rear window defogger (EBL) relay is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns. The EBL relay is a electromechanical device that switches battery current through a fuse in the integrated power module (IPM) to the rear window defogger grid and switches battery current through a positive thermal coefficient (PTC) in the IPM to the outside mirror heating grids. The EBL relay is energized when the relay coil is provided a ground path by the control circuitry within the front control module (FCM). The ISO-standard rear window defogger (EBL) relay is an electromechanical switch that uses a low current input controlled by the front control module (FCM) to control the high current output to the rear window defogger grid lines. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the rear window defogger grid lines. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The EBL relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard relay and for complete rear window defogger (EBL) wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 720 Rear Defogger Relay: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. Rear Window Defogger (EBL) Relay 2. Remove the cover from the integrated power module (IPM) located in the engine compartment. NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for EBL relay location. 3. Remove the EBL relay from the IPM. INSTALLATION NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for EBL relay location. 1. Position the EBL relay into the proper receptacle of the integrated power module (IPM). 2. Align the EBL relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Headlamp Washer Motor Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Left Side Engine Compartment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 728 Wiper Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 729 Wiper Control Module: Service and Repair REMOVAL 1. Release the hood latch and open hood. 2. Disconnect and isolate the battery negative cable. 3. Remove the wiper arms. 4. Remove the cowl cover. Wiper Module Wire Connector 5. Disconnect the positive lock on the wiper module wire connector. 6. Disconnect the wiper module wire connector from the engine compartment wire harness. 7. Disconnect the windshield washer hose from coupling outside the module. 8. Disconnect the drain tubes from nipples on bottom of the wiper module. 9. Remove nuts holding wiper module to lower windshield fence. Wiper Module 10. Remove bolts holding the wiper module to the dash panel. 11. Lift wiper module from weld-studs on lower windshield fence. CAUTION: Do not allow wiper module to rest on brake master cylinder reservoir, damage to brake system can result. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 730 12. Remove wiper module. INSTALLATION NOTE:If replacing the wiper tub, the components must be transferred to the new tub. 1. Position the wiper module into the cowl. 2. Install the bolts that secure the wiper module to the dash (WIPER MODULE). Tighten bolts to 17 Nm (150 in. lbs.). 3. Install the nuts that retain the wiper module to the bulkhead fenceline. Tighten nuts to 7 Nm (62 in. lbs.). 4. Connect the drain tubes to the nipples on the wiper module. 5. Connect the windshield washer tube. 6. Connect the wire harness connector to the wiper module (WIPER MODULE). 7. Connect the positive lock on the wiper module wire connector (WIPER MODULE WIRE CONNECTOR). CAUTION: Do not allow wiper module to rest on brake master cylinder reservoir, damage to brake system can result. 8. Install the cowl cover. 9. Install the wiper arms and blades. Tighten nuts to 37 Nm (27 ft. lbs.). 10. Connect the battery negative cable. 11. Close the hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component Locations Hood Sensor/Switch (For Alarm): Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component Locations > Page 740 Left Side Engine Compartment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 741 Hood Sensor/Switch (For Alarm): Service and Repair HOOD AJAR SWITCH-EXPORT REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a small flat blade screwdriver, pry trigger switch from the bracket on the left fender well. 3. Disconnect the hood ajar switch from the wire connector and remove from vehicle. INSTALLATION 1. Connect the hood ajar switch to the wire connector. 2. Press the hood ajar switch into position on the bracket located on the left inner fender well. 3. Reconnect the battery negative cable. 4. Close the hood and check for proper operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Lock Cylinder Switch: Locations Driver Door Passenger Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 745 Right Cylinder Lock Switch (Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams Parking Assist Distance Sensor: Diagrams Park Assist Sensor No.7 (Parktronics) Park Assist Sensor No.8 (Parktronics) Park Assist Sensor No.9 (Parktronics) Park Assist Sensor No.10 (Parktronics) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 749 Parking Assist Distance Sensor: Description and Operation Park Assist Sensor Park Assist Sensor Location The Park Assist Sensors are located in the rear bumper fascia mounted equally apart. The sensors generate ultrasonic pulses when triggered by the park assist module when an obstacle is detected. The sensors then signal the module when reflected ultrasonic pulses are received. The sensors detect objects with an ultrasonic pulse that reflects off the object and then is sent to the module to determine the distance of the object. The Park Assist Sensors: - Generate ultrasonic pulses when triggered by the Park Assist Module. - Reception/filtering of ultrasonic energy received. - Signalling the module of received ultrasonic pulses that meet threshold criteria. The sensors are supplied power by the module. The sensor supply is enabled when the sensor function is necessary. The sensors detection length from the rear of the vehicle is 0.3 meters to 1.5 meters. This area extends around the rear side of the vehicle. The sensor detection height from the ground is 0.2 meters to about 1.5 meters. - Ensure that the rear bumper (sensors) is free of dirt and debris to keep the system operating properly. - Jackhammers, large trucks, and other vibrations could affect the performance of the system. - Ensure that the parking brake is not applied. If "Service Park Assist System" appears in the EVIC after making sure the rear bumper is clean, proceed to diagnose the system using a scan tool and the appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 750 Parking Assist Distance Sensor: Service and Repair REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Remove rear fascia. Sensor Retaining Clip 4. Remove the sensor retaining clip from the back side of the fascia. Sensor - Remove/Install 5. Push the Park Assist Sensor out of the fascia. INSTALLATION 1. Position the Park Assist Sensor over the retaining housing and firmly snap into housing in rear fascia. 2. Install the rear fascia. 3. Connect the battery negative cable. 4. Close hood. 5. Verify vehicle and system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Diagrams Adjustable Pedals Sensor (Memory Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 757 Adjustable Pedals Switch (Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 758 Pedal Positioning Switch: Service and Repair ADJUSTABLE PEDALS SWITCH REMOVAL The adjustable pedals switch is located in the steering column lower shroud. Remove the shroud, then remove the switch. INSTALLATION The adjustable pedals switch is located in the steering column lower shroud. Install the switch in the shroud, then install the shroud. Once installed, test for proper operation of the adjustable pedals. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams Right Remote Radio Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 762 Remote Switch: Description and Operation Remote Radio Switch Operational View Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). These switches are resistor multiplexed units that are hard-wired to the Body Control Module (BCM) through the clockspring. The BCM sends the proper messages on the Programmable Communications Interface (PCI) data bus network to the radio receiver. For diagnosis of the BCM or the PCI data bus, the use of a DRB III(R) scan tool and the proper Diagnostic Procedures manual are recommended. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 763 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Any diagnosis of the Audio system should begin with the use of the DRB III (R) diagnostic tool. 1. Disconnect and isolate the battery negative cable. Remote Radio Switches 2. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test 3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test table. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in drivers seat. 4. If the switch resistance checks OK, go to Step 5. If not OK, replace the faulty switch. 5. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open circuit as required. 6. Unplug the 24-way white wire harness connector from the Body Control Module (BCM). Check for continuity between the radio control circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to Step 7. If not OK, repair the short circuit as required. 7. Check for continuity between the radio control circuit cavities of the remote radio switch wire harness connector and the BCM wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures manual to test the BCM and the PCI data bus. If not OK, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 764 repair the open circuit as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 765 Remote Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag. 3. Remove the steering wheel. 4. Unplug the wire harness connector from the remote radio switch(es). 5. Remove three screws securing steering wheel rear cover. 6. Remove the remote radio switch from the steering wheel by depressing tabs on each side of each switch. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in drivers seat. INSTALLATION 1. Install remote radio switch to the steering wheel. 2. Install three screws securing steering wheel rear cover. 3. Connect the wire harness to the remote radio switch. 4. Install the steering wheel. 5. Install the driver side airbag. 6. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Ultrasonic Sensor, Antitheft > Component Information > Locations Ultrasonic Sensor: Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Ultrasonic Sensor, Antitheft > Component Information > Locations > Page 769 Ultrasonic Sensor: Diagrams Front Intrusion Sensor (United Kingdom) Rear Instrusion Sensor (United Kingdom) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations > Page 774 Left Cylinder Lock Switch (EXport) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations > Page 775 Door Lock Cylinder Switch: Description and Operation The Door Cylinder Lock Switch (If equipped) is used to: - Unlock/Lock all the doors via the Central Locking feature. - Arm/Disarm the Vehicle Theft Security System. - Trigger the Illuminated Entry feature. The door cylinder lock switch is mounted to the rear of the driver door lock cylinder. When installed on the rear of the cylinder, there is a tab on the lock cylinder that aligns with the switch to prevent it from turning. An anti-rotating device. The door cylinder lock switch is a one time use switch. Once it is removed from the rear of the door lock cylinder, it may not be reinstalled and a new switch must be used. When the Door Cylinder Lock Switch is turned either way using the door key cylinder, the BCM reads a direct message signal from the switch. If turning the key cylinder once, toward the front of the vehicle, this will: 1. Mechanically unlock the door lock. 2. Disarm the Vehicle Theft Security System (if equipped). 3. Turn on the Illuminated Entry (if equipped) for approximately 30 seconds. If the key cylinder is turned to the unlock position (toward the front of vehicle) twice within two seconds, all the doors and liftgate will unlock (if equipped with the central locking feature). To lock the vehicle using the door cylinder lock switch, turn the key cylinder toward the rear of the vehicle once. This will lock the door that you are using the key on. If equipped with the central locking feature, this will lock all the other doors and liftgate. Furthermore, this will arm the vehicle theft security system and turn off the illuminated entry. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations > Page 776 Door Lock Cylinder Switch: Testing and Inspection Door Cylinder Lock Switch Resistance Any diagnosis of the power lock system should begin with the use of the DRB III (R) diagnostic tool. 1. Visually inspect the switch for proper installation. Make sure it is seated on the rear of the key cylinder, with the tab of the door key cylinder properly aligned with the slot on the door cylinder lock switch. 2. Disconnect the switch at the harness connector and check the resistance in each switch position. CAUTION: Do not disconnect the switch from the rear of the door key cylinder. This switch is a one time use switch. Once it is removed from the rear of the switch, it is not reusable and must be replaced. Test the switch at the harness connector. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations > Page 777 Door Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel of the effected door cylinder lock switch. 3. Close the door window. 4. Disconnect the door cylinder lock switch wire connector from the door harness, and wiring clip from the impact beam. 5. Remove the outer door handle from the door. 6. Remove the switch from the key cylinder in the door handle and remove from vehicle. INSTALLATION 1. Install the switch on the key cylinder in the door handle. 2. Install the door handle. 3. Connect the door cylinder lock switch wire connector to the door harness, and the wiring clip to the impact beam. 4. Install the door trim panel of the affected door cylinder lock switch. 5. Connect the battery negative cable. 6. Verify system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component Locations Hood Sensor/Switch (For Alarm): Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component Locations > Page 783 Left Side Engine Compartment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 784 Hood Sensor/Switch (For Alarm): Service and Repair HOOD AJAR SWITCH-EXPORT REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a small flat blade screwdriver, pry trigger switch from the bracket on the left fender well. 3. Disconnect the hood ajar switch from the wire connector and remove from vehicle. INSTALLATION 1. Connect the hood ajar switch to the wire connector. 2. Press the hood ajar switch into position on the bracket located on the left inner fender well. 3. Reconnect the battery negative cable. 4. Close the hood and check for proper operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Diagrams Adjustable Pedals Sensor (Memory Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 791 Adjustable Pedals Switch (Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 792 Pedal Positioning Switch: Service and Repair ADJUSTABLE PEDALS SWITCH REMOVAL The adjustable pedals switch is located in the steering column lower shroud. Remove the shroud, then remove the switch. INSTALLATION The adjustable pedals switch is located in the steering column lower shroud. Install the switch in the shroud, then install the shroud. Once installed, test for proper operation of the adjustable pedals. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Component Locations Power Door Lock Switch: Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Component Locations > Page 797 Passenger Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 798 Power Door Lock Switch: Diagrams Driver Door Lock Switch Passenger Door Lock Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 799 Power Door Lock Switch: Testing and Inspection Door Lock Switch Continuity 1. Remove door trim panel. 2. Disconnect wire connector from back of door lock switch. 3. Depress switch to LOCK position. Door Lock Switch 4. Using an ohmmeter, test switch resistance between Pins 2 and 3. 5. Depress switch to UNLOCK position. 6. Test resistance between Pins 2 and 3. 7. Test resistance between pins 2 and 3 while switch is in its normal unactuated mode. 8. If resistance values are not within the parameters shown replace the door lock switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 800 Power Door Lock Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove door trim panel. 3. Disconnect wire connector from back of door lock switch. 4. Remove two screws to door lock switch. 5. Remove switch from vehicle. INSTALLATION 1. Install the switch into the vehicle. 2. Install the two screws to door lock switch. 3. Connect wire connector to back of door lock switch. 4. Install door trim panel. 5. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Right Side Instrument Panel Lower RHD Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 804 Power Mirror Switch: Diagrams Power Folding Mirror Switch (Export) Power Mirror Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 805 Power Mirror Switch: Description and Operation POWER FOLDAWAY MIRROR SWITCH-EXPORT Power Foldway Mirror Switch These vehicles may be equipped with Power Fold-away Mirrors. This feature allows both the driver and passenger side view mirrors to fold inward (retract) on demand. The vehicle has an additional switch located on the steering column that controls the folding function of the mirror assembly. The fold-away side view mirror is attached to the vehicle's door in the same manner as mirrors without the fold-away option. The fold-away mirrors unique option is the internal motor which allows the mirrors to fold inward on demand. The fold-away mirror motor is not serviceable separately and if a motor is found to be faulty the entire side view mirror must be replaced. When the mirror retract switch is depressed, both of the side view mirrors will fold inward, Thus making the overall width of the vehicle the smallest possible. This can be helpful were parking space is a absolute minimum. When the driver's door is opened, only the driver's door mirror will unfold. If the passenger door is opened, both mirrors will unfold. The power fold away mirror system consists of the following components: mirror switch, side view mirror, relay, wires and fuse. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 806 Power Mirror Switch: Testing and Inspection REMOTE SWITCH Mirror Switch Test Part 1 Mirror Switch Test Part 2 1. Remove power mirror switch. 2. Disconnect wiring harness at switch connector. Mirror Switch 3. Using a ohmmeter, test for continuity between the terminals of the switch. 4. If results shown in the table are not obtained, replace the switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Foldaway Mirror Switch- Export Power Mirror Switch: Service and Repair Power Foldaway Mirror Switch- Export REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the upper and lower steering column shroud. 3. Disconnect electrical harness connector. Power Folding Mirror Switch 4. Remove switch from steering column shroud. INSTALLATION 1. Install switch to steering column shroud. 2. Connect wire harness connector. 3. Install the upper and lower steering column shroud. 4. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Foldaway Mirror Switch- Export > Page 809 Power Mirror Switch: Service and Repair Remote Switch REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel lower cover. 3. From behind headlamp switch assembly, depress retaining tabs and push switch from instrument panel. 4. Disconnect wire connector from power mirror switch. 5. Disengage lock tabs above and below the mirror switch. 6. Remove power mirror switch from headlamp switch bezel. INSTALLATION 1. Install power mirror switch to the headlamp switch bezel. 2. Connect wire connector to the power mirror switch. 3. Insert headlamp switch assembly into instrument panel. 4. Install instrument panel lower cover. 5. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams Power Seat Motor Position Sensor: Diagrams Driver Power Seat Front Riser Position Sensor Driver Power Seat Horizontal Position Sensor Driver Power Seat Rear Riser Position Motor Driver Power Seat Recliner Position Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Power Seat Switch: Diagrams Driver Power Seat Switch Passenger Power Seat Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 816 Power Seat Switch: Description and Operation SEAT SWITCH Power Seat Switch Location Vehicles equipped with a driver side power seat utilize an eight-way power seat switch. Vehicles equipped with a passenger side power seat utilize a four-way power seat switch. These power seat switches features two knobs ganged together on the outboard seat cushion side shield. The switch is secured to the back of the seat cushion side shield with two screws. However, the control knobs for the seat switch unit must be removed before the seat switch can be removed from the side shield. The power seat switch cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. When a power seat switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 817 Power Seat Switch: Testing and Inspection SEAT SWITCH 1. Remove the power seat switch. 2. Using an ohmmeter, check pin #1 of the power seat switch wire harness connector for continuity to ground. It should be present. If OK, go to Step 3. If not OK, repair the open ground circuit as required. 3. Using a voltmeter, check pin #5 of the power seat switch wire harness connector for battery current. It should be present. If OK, go to Step 4. If not OK, repair the open voltage supply circuit as required. Seat Switch Seat Switch Pin-Out 4. Using an ohmmeter, test the power seat switch for continuity, refer to SEAT SWITCH CONTINUITY TEST TABLE. If continuity is not present as indicated, replace the power seat switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 818 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Removing Switch Control Knobs - Typical 2. Using a push pin remover or other suitable wide flat-bladed tool, gently pry the power seat and power recliner switch knobs off of the switch levers. 3. Remove the screws that secure the outboard seat cushion side cover to the seat cushion frame. 4. Pull the outboard seat cushion side cover away from the seat cushion frame far enough to access the power seat switch wire harness connector. 5. Disconnect the power seat wire harness connector from the power seat switch connector receptacle. 6. Remove the screws that secure the power seat switch to the inside of the outboard seat cushion side cover. 7. Remove the power seat switch from the outboard seat cushion side cover. INSTALLATION 1. Position the power seat switch onto the outboard seat cushion side cover. 2. Install and tighten the screws that secure the power seat switch to the inside of the outboard seat cushion side cover. Tighten the screws to 1.5 Nm (14 in. lbs.). 3. Reconnect the power seat wire harness connector to the power seat switch connector receptacle. 4. Install the outboard seat cushion side cover. 5. Install the power seat and power recliner switch knobs onto the switch control levers. 6. Reconnect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Locations > Page 822 Power Sliding Door Switch: Diagrams Left B.Pillar Switch (Power Sliding Door) Left Full Open Switch (Power Sliding Door) Right B.Pillar Switch (power Sliding Door) Right Full Open Switch (Power Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Locations > Page 823 Right Sliding Door Latch Sensing Switch (Power Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Description and Operation > Full Open Switch Power Sliding Door Switch: Description and Operation Full Open Switch Full Open Switch Position And Orientation The full open switch is located in the hold open latch under the sliding door lower hinge. When the power sliding door control module receives a ground signal input from the full open switch, and as long as the cinching latch actuator is not in power mode or the handle switch is open, the signal indicates that the door is at the full open position. The full open switch is incorporated into the hold open latch. If the full open switch is inoperative, the entire hold open latch assembly must be replaced. The full open switch is triggered by a pawl lever in the hold open latch. When the full open switch is closed (circuit to ground) the ratchet has engaged on the hold open striker and the pawl lever has engaged on the ratchet, locking the latch from opening and holding the door in the full open position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Description and Operation > Full Open Switch > Page 826 Power Sliding Door Switch: Description and Operation B-Pillar Switch The B-pillar switches are located on the interior of the vehicle, on the B-pillar trim panels. These switches serve as an open and close command switch for the appropriate power sliding door. When the B-pillar switch is depressed a signal is sent to the Body Control Module (BCM), this signal is then sent to the power sliding door control module, telling it to start a power open or close cycle. The child lockout feature must be disabled and the sliding door must be unlocked in order for the B-pillar switch to function. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Description and Operation > Page 827 Power Sliding Door Switch: Service and Repair B-PILLAR SWITCH REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick (special tool # C-4755) or equivalent, gently pry the leading upper edge of the B-pillar switch away from the B-pillar trim. 3. Once the upper edge is free from B-pillar trim, rock the switch out of the switch opening. 4. Disconnect the B-pillar switch electrical connector. First, slide the connector lock away from the switch then, depress connector retaining tab while pulling straight apart. 5. Remove the B-pillar switch from the vehicle. INSTALLATION 1. Connect the B-pillar switch electrical connector. Slide connector lock toward the switch to lock in place. 2. Hook the lower edge of the B-pillar switch on the B-pillar trim and then push the switch firmly into position. 3. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Locations > Page 831 Power Trunk / Liftgate Hazard Sensor: Description and Operation Pinch sensors are located on each side of the lift-gate. These sensors look like weather-strips, however they consist of pieces of electrically conductive rubber (tapeswitch), wires, resistor, double sided tape, and a plastic carrier. They are used to indicate an obstruction during a power liftgate close cycle. During a power liftgate close cycle, if either of the two conductive rubber strips (tapeswitch) of the pinch sensor come in contact with an obstacle, the pinch sensor circuit is completed. This tells the power liftgate control module that a obstruction is felt. The control module will stop the liftgate immediately and return it to the full open position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Locations > Page 832 Power Trunk / Liftgate Hazard Sensor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove trim panel from liftgate. Pinch Sensor Location 3. Disconnect the pinch sensor wire harness connector. 4. Remove screws holding the pinch sensor to lift-gate. 5. Feed the pinch sensor wire harness out of the liftgate and remove the sensor from the vehicle. INSTALLATION WARNING: USE EXTREME CAUTION WHEN TESTING PINCH SENSOR OPERATION. CAUTION: Ensure liftgate surface is clean and dry prior to pinch sensor installation. Failure to do so will inhibit the adhesive backings ability to adhere to the liftgate and cause improper system operation or premature component failure. 1. Position the pinch sensor to the liftgate. 2. Install the third screw from the top of the sensor first. Do not torque screw at this time. 3. Install the remaining three screws holding the sensor to the liftgate. Torque all screws to 25 in. lbs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Locations > Page 833 Pinch Sensor Location 4. Install wire harness grommet in liftgate flange and route, connect the pinch sensor wire harness connector. 5. Remove protective tape from the top of the pinch sensor. Firmly apply pressure to the sensor adhesive to secure it to the liftgate. 6. Install the trim panel on the liftgate. 7. Connect the battery negative cable. 8. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes related to the pinch sensor. 9. Verify power liftgate system and pinch sensor operation. Cycle the power liftgate through one complete open and close cycle, during the final close cycle press the pinch sensor to verify the power liftgate detects an obstruction and returns to the full open position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 837 Power Trunk / Liftgate Lock Switch: Diagrams Liftgate Ajar Switch (Manual Release) Liftgate Ajar Switch (power Release) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation Seat Heater Sensor: Description and Operation Two heated seat sensors are used per vehicle, one in each front seat cushion heating element. The heated seat temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. The heated seat sensors cannot be repaired or adjusted and if found to be faulty, the complete heated seat cushion element must be replaced. The temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. When the temperature of the seat cushion cover rises, the resistance of the sensor decreases. The heated seat module supplies a five-volt current to one side of each sensor, and monitors the voltage drop through the sensor on a return circuit. The heated seat module uses this temperature sensor input to monitor the temperature of the seat, and regulates the current flow to the seat heating elements accordingly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation > Page 841 Seat Heater Sensor: Testing and Inspection NOTE: When checking heated seat elements for continuity, be certain to move the heating element being checked. Moving the element, such as sitting in the seat will eliminate the possibility of an intermittent open in the element which would only be evident if the element was in a certain position. Failure to check the element in various positions could result in an incomplete test. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. Disconnect the black 4-way cushion heating element wire harness connector. 2. Using an ohmmeter, check the resistance between cavities "B" and "C". The sensor resistance should be between 50 kilohms at 15° C (60° F) and 2 kilohms at 30° C (85° F). If not OK, replace the faulty seat element and sensor assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation Seat Heater Switch: Description and Operation Heated Seat Switch Location The heated seat switches are mounted in the instrument panel center bezel. The two three-position rocker-type switches, one switch for each front seat, are incorporated into one large switch assembly that also includes the hazard, rear window wiper and washer switches. Each heated seat switch provides a resistor multiplexed signal to its respective Heated Seat Module (HSM) through separate hard wired circuits. Each switch has an Off, Low, and High position so that both the driver and the front seat passenger can select a preferred seat heating mode. Each switch has two Light-Emitting Diodes (LED) which light to indicate that the heater for the seat is turned on. The heated seat switches and their LEDs cannot be repaired. If either switch or LED is faulty or damaged, the entire switch assembly must be replaced. There are three positions that can be selected with each of the heated seat switches: Off, Low, or High. When the left side of the switch rocker is fully depressed, the Low position is selected and the low position LED indicator illuminates. When the right side of the switch rocker is fully depressed, the High position is selected and the high position LED indicator illuminates. When the switch rocker is moved to its neutral position (middle), Off is selected and both LED indicators are extinguished. Each switch provides separate resistor, hard wire inputs to its respective Heated Seat Module (HSM) to indicate the selected switch position. The heated seat module responds to the heated seat switch status messages by controlling the output to the seat heater elements of the selected seat. The Low heat position set point is about 36° C (97° F), and the High heat position set point is about 40° C (105° F). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 845 Seat Heater Switch: Testing and Inspection DRIVER HEATED SEAT SWITCH Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. WARNING: REFER TO THE RESTRAINTS OF THIS MANUAL BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. CHECKING SWITCH SIGNAL AND WIRING AT THE MODULE - EARLY BUILD VEHICLES 1. Disconnect and isolate the battery negative cable. 2. Access and disconnect the gray 4-way connector from the heated seat module. Visually inspect wiring terminals for damage that would prevent positive connection. If not OK, repair or replace the necessary components. 3. Connect the battery negative cable. Place the heated seat switch in the LO position. Using an Ohmmeter, check the resistance between cavities 2 and 3 of the gray connector noted above. Resistance should be about 3.5 kilohms (3500 ohms). If not OK, check resistance directly at switch, as noted below. If OK, proceed to the next step. If not OK, replace the faulty switch. 4. Place the heated seat switch in the HI position. Using an ohmmeter, check the resistance between cavities 2 and 3 of the gray connector noted above. Resistance should be about 1.4 kilohms (1400 ohms). If not OK, check resistance directly at the switch, as indicated in the Heated Seat Switch Test Table. If OK, proceed. If not OK replace the faulty switch. 5. With the system ON in the HI position, check for battery voltage and ground at cavities 4 and 1. If OK, proceed with testing remaining components. If not OK, repair open or shorted wiring. CHECKING SWITCH SIGNAL AND WIRING AT THE MODULE - LATE BUILD VEHICLES 1. Disconnect and isolate the battery negative cable. 2. Access and disconnect the black 8-way connector from the main seat harness. Visually inspect wiring terminals for damage that would prevent positive connection. If not OK, repair or replace the necessary components. 3. Connect the battery negative cable. Place the heated seat switch in the LO position. Using an Ohmmeter, check the resistance between cavities 3 and 5 of the black 8-way connector noted above. Resistance should be about 3.5 kilohms (3500 ohms). If not OK, check resistance directly at switch, as noted below. If OK, proceed to the next step. If not OK, replace the faulty switch. 4. Place the heated seat switch in the HI position. Using an ohmmeter, check the resistance between cavities 3 and 5 of the black 8-way connector noted above. Resistance should be about 1.4 kilohms (1400 ohms). If not OK, check resistance directly at the switch, as indicated in the Heated Seat Switch Test Table. If OK, proceed. If not OK replace the faulty switch. 5. With the system ON in the HI position, check for battery voltage and ground at cavities 4 and 5. If OK, proceed with testing remaining components. If not OK, repair open or shorted wiring. CHECKING SWITCH ONLY 1. Disconnect and isolate the battery negative cable. Remove the center bezel from the instrument panel. Check for continuity between the ground circuit cavity (#10) of the instrument panel center bezel switch electrical connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground as required. 2. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the instrument panel center bezel switch electrical connector (#4). If OK, turn the ignition switch to the Off position, and go to Step 3. If not OK, repair the open fused ignition switch output (run) circuit as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 846 Instrument Panel Center Bezel Switch Connector Switch Retaining Screws 3. Test the heated seat switch as shown in the Heated Seat Switch Test chart and the connector pin-out below. If OK, go to Step 4. If not OK, replace the instrument panel center bezel switch assembly. 4. Connect the instrument panel center bezel switch and test the heated seat system for proper operation. If the system is still inoperative proceed with checking remaining components. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 847 Seat Heater Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO THE RESTRAINTS OF THIS MANUAL BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. Switch Retaining Screws 3. Remove the three screws that secure the heated seat switch to the back of the instrument panel center bezel. 4. Remove the heated seat switch from the back of the instrument panel center bezel. INSTALLATION 1. Position the heated seat switch onto the back of the instrument panel center bezel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 848 Switch Retaining Screws 2. Install and tighten the three screws that secure the heated seat switch to the back of the instrument panel center bezel. Tighten the screws to 1.5 N.m (13 in. lbs.). 3. Install the center bezel onto the instrument panel. 4. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations Driver Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 852 Memory Set Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 853 Seat Memory Switch: Description and Operation Memory Switch Location Vehicles equipped with the memory system have a memory switch mounted to the driver side front door trim panel. This switch is used to set and recall all of the memory system settings for up to two drivers. The memory switch is a resistor multiplexed unit that is hard wired to the Body Control Module (BCM). The BCM sends out the memory system set and recall requests to the other electronic modules over the Programmable Communications Interface (PCI) data bus. The memory switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The memory switch has three momentary switch buttons labeled Set, 1 and 2. When the memory set switch is depressed, a resistance value is sent to the Body Control Module (BCM) via hard wired connections. When the memory system is in "set" mode a chime will be generated by the BCM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 854 Seat Memory Switch: Testing and Inspection MEMORY SWITCH Memory Switch Test Table 1. Remove the memory switch from the drivers door panel. 2. Using an ohmmeter, check the continuity of the memory select switch MUX circuit between the C2 wire harness connector for the Body Control Module (BCM) and the wire harness connector for the memory switch. There should be continuity. If OK, go to Step 3. If not OK, repair the open or shorted MUX circuit as required. 3. Using an ohmmeter, check the continuity of the memory select switch return circuit between the C2 wire harness connector for the BCM and the wire harness connector for the memory switch. There should be continuity. If OK, go to Step 4. If not OK, repair the open or shorted return circuit as required. 4. Using an ohmmeter, test the resistances of the memory switch. If OK, refer to Body and Frame / Seats / Testing and Inspection. If not OK, replace the memory switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 855 Seat Memory Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door trim panel switch bezel from the driver side front door. Using a thin flat-bladed pry tool, gently pry the switch bezel away from the drivers door trim panel. 3. Disconnect the memory switch wire harness connector from the memory switch. 4. Remove the two screws that secure the memory switch to the back of the driver side front door trim panel switch bezel. 5. Remove the memory switch. INSTALLATION 1. Position the memory switch and install and tighten the two screws that secure the memory switch to the back of the driver side front door trim panel switch bezel. Tighten the screws to 2.2 Nm (20 in. lbs.). 2. Reconnect the memory switch wire harness connector to the memory switch. 3. Install the trim panel switch bezel onto the driver side front door. 4. Reconnect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Sunroof Module (Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 859 Sunroof / Moonroof Switch: Description and Operation Power Sunroof Switch The power sunroof switch is a combination pushbutton and rocker switch mounted in the overhead console. The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/ module assembly. The sunroof switch performs the following functions: - Power sunroof open - Power sunroof closed - Power sunroof vent The sunroof is electrically operated from two switches located on the windshield header, rearward of the map lamp. The "VENT" switch is a push button type switch and opens the sunroof to the vent position only. The other switch "OPEN/CLOSED" is a rocker type switch for opening and closing the sunroof. Pressing and releasing the open button once, the sunroof will express open and the wind deflector will raise. If the button is pressed a second time the sunroof will stop in that position. Pressing and holding the close button will close the sunroof. If the close button is released the sunroof will stop in that position. The switch is grounded at one terminal and receives a 12 volt signal from the sunroof motor/module on the remaining three terminals. The switch pulls down the 12 volt reference voltage from the motor/ module signaling it to perform the desired function. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 860 Sunroof / Moonroof Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Perform the following test prior to switch replacement. 1. Remove the overhead console. 2. Disconnect the power sunroof switch wire harness connector. 3. With the ignition key in the "RUN" position check for battery voltage on the "OPEN", "CLOSE" and "VENT" circuits of the sunroof switch harness connector. If OK, go to Step 4. If not OK, inspect the wiring harness and connectors between the motor/ module and switch for damage and repair as necessary. 4. With the ignition key in the "OFF" position check for continuity between the ground circuit of the sunroof switch harness connector and a known good ground. Continuity should be present. If OK, go to Step 5. If not OK, inspect the wiring harness and connector and repair the ground circuit as necessary. Sunroof Switch Pinout Power Sunroof Switch Continuity Table 5. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. If OK, inspect the wiring harness and connectors for damage and repair as necessary. If not OK, replace the power sunroof switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 861 Sunroof / Moonroof Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Overhead Console 2. Separate the overhead console from the head-liner, by carefully pulling down on the front portion, toward the windshield, to release the retaining clips. 3. Release the sunroof switch retaining tab, disconnect the electrical connector and remove the switch from the overhead console. INSTALLATION Overhead Console 1. Position the sunroof switch against the overhead console and push the switch to properly seat in retaining clip. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 862 2. Install the overhead console assembly. 3. Connect the battery negative cable. 4. Confirm proper sunroof system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Description and Operation > Exterior Handle Switch Trunk / Liftgate Switch: Description and Operation Exterior Handle Switch The exterior handle switch is an electronic release switch mounted to the rear license plate lamp housing assembly, located just above the license plate. This switch controls the power liftgate release function and is also capable of reversing the power lift-gate when it is in motion. A full power open cycle cannot be performed using this switch, only one of the power open command switches (key fob and overhead console mounted) can be used to perform a full power open cycle. The exterior handle switch is a serviceable component. When the exterior handle switch is depressed, with the liftgate in the closed position, a message is sent to the Body Control Module (BCM). The BCM then sends a signal to the power liftgate control module via the Programmable Communication Interface (PCI) data bus circuit. The power liftgate control module then sends a signal to the power latch mounted actuator, which moves the liftgate from the primary closed and latched position to the open and movable position. If the liftgate is not pulled open once the latch releases within a few seconds, the latch will cinch closed again. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Description and Operation > Exterior Handle Switch > Page 867 Trunk / Liftgate Switch: Description and Operation Full Open Switch Full Open Switch Location The full open switch is located on the gear motor housing and is used to signal the power lift-gate control module when the power liftgate is in the full open position. Two wires are used from the full open switch contacts to the gear motor assemblies main electrical connector. The full open switch is a serviceable component. When the power liftgate reaches the full open position, the gear motor housing mounted full open switch electrical contacts close. This sends a ground signal to the power liftgate control module, telling the module that the liftgate has reached the full open position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Exterior Handle Switch Trunk / Liftgate Switch: Service and Repair Exterior Handle Switch REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the liftgate and remove the liftgate trim panel. 3. Remove the rear lamp bar assembly from the vehicle. 4. Locate the two wires going to the exterior handle switch. Cut the tie strap and trace the wires to the large electrical connector and back the wires out of the large connector and through the grommet. Take care to mark the location of the wire terminals in relation to the large connector so that they are positioned in the appropriate cavities upon switch installation. Rear Light Bar 5. Depress the two exterior handle switch retaining tabs and roll the switch out of the light bar assembly. INSTALLATION Rear Light Bar 1. Install the handle switch in the light bar assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Exterior Handle Switch > Page 870 2. Locate the two wires going to the exterior handle switch. Install the wires through the grommet and in the large connector. Secure with a tie strap. NOTE: Be certain wires are reinstalled in the correct wire cavities. Failure to do so could result in damage to the handle switch. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. 3. Install the rear light bar. 4. Install the liftgate trim panel. 5. Connect the battery negative cable. 6. Using an appropriate scan tool, check any erase any power liftgate control module diagnostic trouble codes. 7. Verify power liftgate system and handle switch operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Exterior Handle Switch > Page 871 Trunk / Liftgate Switch: Service and Repair Full Open Switch REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lift gear and link rod assembly from the vehicle 3. Cut the two wires leading to the full open switch or back the wires out of the electrical connector. 4. Remove the full open switch retaining screw and remove the full open switch from the gear motor housing assembly. INSTALLATION 1. Perform a wiring repair on the full open switch wires following the approved procedure in the Wiring section. Or install new terminals on the wire ends and reinstall in the main lift-gate motor electrical connector. 2. Position and install the full open switch retaining screw. 3. Install the power liftgate lift gear and link rod assembly. 4. Connect the battery negative cable. 5. Using an appropriate scan tool, check any erase any power liftgate control module diagnostic trouble codes. 6. Verify power liftgate system and full open switch operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Left Side Engine Compartment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 876 Brake Fluid Level Sensor/Switch: Description and Operation BRAKE FLUID LEVEL SWITCH DESCRIPTION The brake fluid level switch is located in the brake fluid reservoir of the master cylinder (Fig. 3). OPERATION The purpose of the brake fluid level switch is to provide the driver with an early warning that the brake fluid level in the master cylinder fluid reservoir has dropped below a normal level. This may indicate: ^ Abnormal loss of brake fluid in the master cylinder fluid reservoir resulting from a leak in the hydraulic system. ^ Brake shoe linings which have worn to a point requiring replacement. As the brake fluid drops below the minimum level, the brake fluid level switch closes to complete the red BRAKE warning indicator (lamp) circuit. This will turn on the red BRAKE warning indicator. The master cylinder fluid reservoir should be checked and refilled to the Full mark with DOT 3 brake fluid. If the brake fluid level has dropped below the add line in the master cylinder fluid reservoir, the entire brake hydraulic system should be checked for evidence of a leak. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 877 Brake Fluid Level Sensor/Switch: Service and Repair BRAKE FLUID LEVEL SWITCH REMOVAL 1. Remove wiring harness connector from brake fluid reservoir level switch (Fig. 3). 2. Using fingers, compress the retaining tabs on the opposite end of brake fluid level switch. 3. With retaining tabs compressed, grasp the connector end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. INSTALLATION 1. Insert brake fluid level switch into left side of brake fluid reservoir. Be sure switch is pushed in until retaining tabs lock it to brake fluid reservoir. 2. Connect vehicle wiring harness connector to brake fluid level switch (Fig. 3). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams Brake Fluid Level Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations > Page 885 Traction Control Switch: Connector Locations Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations > Page 886 Steering Column Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 887 Traction Control Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 888 Traction Control Switch: Testing and Inspection TRACTION CONTROL SWITCH DIAGNOSIS AND TESTING - TRACTION CONTROL SWITCH 1. Remove lower steering column shroud. 2. Disconnect traction control switch harness from column harness (Fig. 5). 3. Using an ohmmeter, check for continuity between pins 1 and 2. With the switch actuated, there should be continuity between the two pins. With the switch off, there should be no continuity. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 889 Traction Control Switch: Service and Repair TRACTION CONTROL SWITCH REMOVAL The traction control switch is located in the upper shroud. Refer to Steering. INSTALLATION The traction control switch is located in the upper shroud. Refer to Steering. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Brakes - Rear Wheel Speed Sensor Replacement Guidelines Wheel Speed Sensor: Technical Service Bulletins Brakes - Rear Wheel Speed Sensor Replacement Guidelines NUMBER: 05-004-04 REV. A GROUP: Brakes DATE: December 3, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-004-04, DATED SEPTEMBER 2, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. SUBJECT: Anti-lock Brake Rear Wheel Speed Sensor Replacement MODELS: **2001 - 2005 (RG) Chrysler Voyager** 2001 - 2005 (RS) Town & Country/Caravan/Voyager NOTE: This bulletin applies to non-all wheel drive vehicles equipped with anti-lock brakes (sales code BGF). PARTS REQUIRED: DISCUSSION: When replacing a rear wheel speed sensor, upon disassembly, inspect for moisture on the sensor and inside the bearing cap. If moisture is present, the moisture must be dried out prior to reassembly, or the new sensor may be damaged. When installing a replacement wheel speed sensor, be sure to lubricate the sensor 0-ring and the sensor head completely, with Mopar wheel bearing grease, p/n 05083149AA, before installation. NOTE: It is important that only Mopar, p/n 05083149AA, Wheel Bearing Grease, or M56560 equivalent, be used for this application. No other lubricant may be substituted. Other lubricants may cause sensor damage. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 894 Wheel Speed Sensor: Specifications TONE WHEEL RUNOUT WHEEL SPEED SENSOR AIR GAP Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations WHEEL SPEED SENSORS FRONT REAR WHEEL SPEED SENSOR CONNECTORS FRONT Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 897 REAR Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 898 Wheel Speed Sensor: Connector Locations Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 899 Left Fender Shield Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 900 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 901 Left Rear Body Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 902 Right Quarter Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 903 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor Left Rear Wheel Speed Sensor Right Front Wheel Speed Sensor Right Rear Wheel Speed Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 904 Wheel Speed Sensor: Description and Operation ABS SWITCHES/SENSORS Wheel Speed Sensors and Tone Wheels: One active wheel speed sensor (WSS) is located at each wheel. The sensors use an electronic principle known as magneto-resistive to help increase performance, durability and low speed accuracy. The sensors convert wheel speed into a small digital signal. A toothed gear tone wheel serves as the trigger mechanism for each sensor. The CAB/ABM sends 12 volts to power an Integrated Circuit 01C) in the sensor. The IC supplies a constant 7 mA signal to the CAB/ABM. The relationship of the tooth on the tone wheel to the permanent magnet in the sensor, signals the IC of the sensor to toggle a second 7 mA power supply on or off. The output of the sensor, sent to the CAB/ ABM, is a DC voltage signal with changing voltage and current levels. The CAB/ABM monitors the changing amperage (digital signal) from each wheel speed sensor. The resulting signal is interpreted by the CAB/ABM as the wheel speed. Because of internal circuitry, correct wheel speed sensor function cannot be determined by a continuity or resistance check through the sensor. Correct antilock system operation is dependent on tone wheel speed signals from the wheel speed sensors. The vehicle's wheels and tires should all be the same size and type to generate accurate signals. In addition, the tires should be inflated to the recommended pressure for optimum system operation. Variation in wheel and tire size or significant variations in inflation pressure can produce inaccurate wheel speed signals; however, the system will continue to function when using the correct factory mini-spare. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 905 Wheel Speed Sensor: Testing and Inspection TONE WHEEL INSPECTION - TONE WHEEL NOTE: Rear tone wheels for front-wheel-drive vehicles are sealed within the hub and bearing assembly and cannot be inspected or replaced. Replacement of the hub and bearing is necessary. Tone wheels can cause erratic wheel speed sensor signals. Inspect tone wheels for the following possible causes. ^ missing, chipped, or broken teeth ^ contact with the wheel speed sensor ^ wheel speed sensor to tone wheel alignment ^ wheel speed sensor to tone wheel clearance ^ excessive tone wheel runout ^ tone wheel loose on its mounting surface If a front tone wheel is found to need replacement, the drive shaft must be replaced. No attempt should be made to replace just the tone wheel. If wheel speed sensor to tone wheel contact is evident, determine the cause and correct it before replacing the wheel speed sensor or tone wheel. Check the gap between the speed sensor head and the tone wheel to ensure it is within specifications. Excessive wheel speed sensor runout can cause erratic wheel speed sensor signals. Refer to SPECIFICATIONS for the maximum allowed tone wheel runout. If tone wheel runout is excessive, determine if it is caused by a defect in the driveshaft assembly or hub and bearing. Replace as necessary. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Replacement of entire component is necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front FRONT WHEEL SPEED SENSOR REMOVAL 1. Raise vehicle. 2. Remove the tire and wheel assembly. 3. Remove the sensor cable routing clamp screws. CAUTION: When disconnecting the wheel speed sensor from vehicle wiring harness, be careful not to damage pins on connector 4. Remove speed sensor cable grommets from intermediate bracket on strut. 5. Disconnect speed sensor cable from vehicle wiring harness behind fender well shield. 6. Remove the wheel speed sensor head mounting bolt (Fig. 1). 7. Remove sensor head from steering knuckle. If sensor has seized due to corrosion, DO NOT USE PLIERS ON SENSOR HEAD. Use a hammer and a punch and tap edge of sensor ear, rocking the sensor side-to-side until free. 8. Remove front wheel speed sensor from vehicle. INSTALLATION CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as shown may result in contact with moving parts and over extension of cables, resulting in an open circuit. 1. Connect the front wheel speed sensor cable to the vehicle wiring harness connector. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector. 2. Install the bolts attaching the routing clamps to the body of the vehicle. Tighten the bolts to a torque of 14 Nm (125 inch lbs.). 3. Insert speed sensor cable grommets into intermediate bracket on strut. 4. Install the wheel speed sensor head mounting bolt (Fig. 1). Tighten the bolt to a torque of 13 Nm (115 inch lbs.) 5. Install the wheel and tire assembly on vehicle. 6. Lower vehicle. 7. Road test vehicle to ensure proper operation of the base and ABS brake systems. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 908 Wheel Speed Sensor: Service and Repair Rear Rear Wheel Speed Sensor - FWD REAR WHEEL SPEED SENSOR - FWD REMOVAL 1. Raise vehicle. CAUTION: When disconnecting speed sensor cable from vehicle wiring harness be careful not to damage pins on the electrical connectors. Also, inspect connectors for any signs of previous damage. 2. Remove grommet from floor pan of vehicle and disconnect speed sensor cable connector from vehicle wiring harness (Fig. 2). CAUTION: When removing rear wheel speed sensor cable from routing clips, be sure not to damage the routing clips. Routing clips that are molded onto the brake hose will require replacement of the brake hose if damaged during removal or installation of the speed sensor cable. 3. Carefully remove speed sensor cable from press-in routing clips (Fig. 3). 4. Remove bolt securing metal routing clip to rear of axle and remove sensor cable from metal clip (Fig. 3). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 909 5. Remove secondary (yellow) retaining clip at rear of wheel speed sensor head (Fig. 4). 6. Push up on metal retaining clip (Fig. 4) until it bottoms. This will release wheel speed sensor head from hub and bearing. While holding metal clip up, pull back on wheel speed sensor head removing it from hub and bearing. 7. Remove wheel speed sensor assembly from vehicle. INSTALLATION CAUTION: Proper installation of wheel speed sensor cable is critical to continued system operation. Be sure that cable is installed in routing retainers/clips. Failure to install cable in retainers may result in contact with moving parts or over extension of cable, resulting in an open circuit. CAUTION: It is important that only Mopar Wheel Bearing Grease be used for the following step application. Other lubricants may cause sensor failure. 1. Lubricate the sensor O-ring with Mopar Wheel Bearing Grease before installation into the Hub And Bearing. If not lubricated, an improper seal may result due to rolling of the O-ring. 2. If metal sensor retaining clip is not in the neutral installed position on hub and bearing cap, install from the bottom, if necessary, and push clip upward until it snaps into position. 3. Install wheel speed sensor head into rear of hub and bearing aligning index tab with the notch in the top of the mounting hole. Push the sensor in until it snaps into place on the metal retaining clip. 4. Install secondary (yellow) retaining clip over wheel speed sensor head and engage the tabs on each side. 5. Route sensor cable under leaf spring along rear of axle. Install speed sensor cable into routing clips on rear brake flex hose (Fig. 3). 6. Install cable into metal routing clip and attach it to the rear axle with mounting bolt (Fig. 3). Tighten mounting bolt to 16 Nm (140 inch lbs.). 7. Connect wheel speed sensor cable to vehicle wiring harness (Fig. 2). Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector. 8. Install speed sensor cable grommet into hole in floor pan making sure grommet is fully seated into hole. 9. Lower vehicle. 10. Road test vehicle to ensure proper operation of the base and ABS braking systems. Rear Wheel Speed Sensor - AWD REAR WHEEL SPEED SENSOR - AWD REMOVAL 1. Raise vehicle. CAUTION: When disconnecting speed sensor cable from vehicle wiring harness be careful not to damage pins on the electrical connectors. Also, inspect connectors for any signs of previous damage. 2. Remove grommet from floor pan of vehicle and disconnect speed sensor cable connector from vehicle wiring harness. CAUTION: When removing rear wheel speed sensor cable from routing clips, be sure not to damage the routing clips. Routing clips that are molded onto the brake hose will require replacement of the brake hose if damaged during removal or installation of the speed sensor cable. 3. Carefully remove speed sensor cable from press-in routing clips along brake hose and tubing. 4. Remove bolt securing wheel speed sensor cable metal clip to rear of axle. Remove metal clip from cable if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 910 CAUTION: If speed sensor head has seized due to corrosion, do not use pliers on speed sensor head in an attempt to remove it. Use a hammer and a punch and tap mounting flange edge side-to-side, rocking the sensor until free. 5. Remove wheel speed sensor head attaching bolt. 6. Remove wheel speed sensor head from the axle, and remove sensor from vehicle. INSTALLATION CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as indicated may result in contact with moving parts or over-extension of cables, resulting in an open circuit. 1. Install wheel speed sensor head in axle flange. CAUTION: Prior to installing the speed sensor head attaching bolt, the plastic anti-rotation pin must be fully seated into the bearing flange. 2. Install wheel speed sensor head attaching bolt. Tighten bolt to a torque 10 Nm (90 inch lbs.). 3. Check the air gap between the face of the wheel speed sensor and the top surface of the tone wheel. CAUTION: When installing wheel speed sensor cable in the routing clips on rear brake flex hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will require replacement of the brake hose if damaged. 4. Install speed sensor cable under leaf spring onto brake hose and tubing utilizing routing clips to secure it in place. 5. Install metal routing clip on speed sensor cable and mount it to rear of axle with mounting bolt. Tighten mounting bolt to 16 Nm (140 inch lbs.). 6. Connect wheel speed sensor cable to vehicle wiring harness. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector. 7. Install speed sensor cable grommet into the floor pan, being sure the grommet is fully seated into the access hole. 8. Lower vehicle. 9. Road test vehicle to ensure proper operation of the base and ABS braking systems. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Diagrams A/C Pressure Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Speed Control Switches Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 923 Cruise Control Switch: Diagrams Left Speed Control Switch Right Speed Control Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 924 Cruise Control Switch: Service Precautions WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO THE RESTRAINT SYSTEMS SECTION FOR MORE INFORMATION. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 925 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system and are located on the steering wheel. The speed control system has five separate resistive switches that provide a single multiplexed (MUX) voltage inputs to the PCM.The switch names are: ON, OFF, SET, COAST, RESUME, ACCEL, TAPUP COAST, and CANCEL. Based on conditions when the buttons are pushed (and released), the five voltages ranges provided to the PCM result in the following functions: ON, OFF, SET, COAST, RESUME, ACCEL, TAP-UP TAP-DOWN, COAST, and CANCEL. Refer to the Speed Control Section for more information Also the PCM receives an input from the brake switch to sense whether the brake pedal has been depressed. When the PCM receives the brake depressed input, it turns OFF power to the speed control servo and disengages speed control. Also the power to the servo is supplied through the brake switch, which opens the circuit when the brake pedal is depressed. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 926 Cruise Control Switch: Service and Repair REMOVAL The speed control switches are mounted in the steering wheel and wired through the clock spring device under the airbag module. WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO THE RESTRAINT SYSTEMS SECTION FOR MORE INFORMATION. 1. Remove the negative battery cable. 2. Turn OFF ignition. 3. Remove the air bag, refer to the restraint section for more information. 4. Remove the screw from bottom of the switch. 5. Remove switch from steering wheel. 6. Disconnect two-way electrical connector. 7. Repeat for the other switch. INSTALLATION The speed control switches are mounted in the steering wheel and wired through the clock spring device under the airbag module. WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO THE RESTRAINT SYSTEMS SECTION FOR MORE INFORMATION. 1. Connect two-way electrical connector. 2. Install switch. 3. Install screw for the switch. 4. Repeat for the other switch. 5. Install the air bag, refer to the restraint section for more information. 6. Install the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil Pressure Switch ............................................................................................................................. .................................................. 23 Nm (200 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 931 Oil Pressure Sender: Description and Operation DESCRIPTION The engine oil pressure switch is located on the lower left front side of the engine. It screws into the oil filter adapter. The normally closed switch provides an input through a single wire to the low pressure indicator light on the instrument cluster. OPERATION The oil pressure switch provides a ground for the instrument cluster low oil pressure indicator light. The switch receives oil pressure input from the engine main oil gallery. When engine oil pressure is greater than 27.5 Kpa (4 psi), the switch contacts open, providing a open circuit to the low pressure indicator light. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 932 Oil Pressure Sender: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Disconnect electrical connector from switch. 3. Remove oil pressure switch (Fig. 110). INSTALLATION 1. Install oil pressure switch. Torque oil pressure switch to 23 Nm (200 in. lbs.) (Fig. 110). 2. Connect electrical connector to switch. 3. Lower the vehicle. 4. Start engine and check for leaks. 5. Check engine oil level. Adjust as necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Oxygen Sensors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 936 3.3-3.8 Liter Engine Front Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 937 Engine Pressure Switch (GAS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 942 Ambient Temperature Sensor / Switch HVAC: Diagrams Ambient Temperature Sensor ATC Remote Sensor (ATC) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Infrared Temperature Sensor Ambient Temperature Sensor / Switch HVAC: Description and Operation Infrared Temperature Sensor Infrared Temperature Sensor - RS Shown, RG Typical The infrared temperature sensor consists of two infrared transducers that are concealed behind a clear lens located near the top of the instrument panel center bezel. These sensors are used only on models equipped with the optional automatic temperature control (ATC) heating-A/C system. A molded plastic connector receptacle on the bottom of the panel outlet unit is concealed behind the center bezel. A short, dedicated jumper wire harness routed behind the center bezel connects the sensors directly to the ATC A/C-heater control module near the bottom of the center bezel. The infrared temperature sensor is integral to the center bezel panel outlet. The infrared sensor detects thermal radiation emitted by the driver and front passenger seat occupants and their surroundings and converts its data into a linear pulse width modulated (PWM) output signal which is read by the automatic temperature control (ATC) A/C-heater control. The ATC A/C-heater control uses the infrared sensor data as one of the inputs necessary to automatically control the interior cabin temperature level. By using thermal radiation (surface temperature) measurement, rather than an air temperature measurement, the ATC heating-A/C system is able to adjust itself to the comfort level as perceived by the occupant. This allows the ATC system to compensate for other ambient conditions affecting comfort levels, such as solar heat gain or evaporative heat loss. The ATC system logic responds to the infrared sensor message by calculating and adjusting the air flow temperature and air flow rate needed to properly obtain and maintain the selected comfort level temperature of the occupants. The A/C-heater control continually monitors the infrared sensor circuits, and will store diagnostic trouble codes (DTCs) for any problem it detects. The infrared sensor is diagnosed using a DRBIII(R) scan tool. The infrared sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Infrared Temperature Sensor > Page 945 Ambient Temperature Sensor / Switch HVAC: Description and Operation Ambient Temp Sensor Ambient air temperature is monitored by the overhead console through ambient temperature messages received from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus circuit. The PCM receives a hard wired input from the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the headlamp mounting module grille opening, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent by the Powertrain Control Module (PCM). The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the PCM. Based upon the resistance in the sensor, the PCM senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. The PCM then sends the proper ambient temperature messages to the Electronic Vehicle Information Center (EVIC)/Compass Mini-Trip Computer (CMTC) over the Programmable Communication Interface (PCI) data bus. The thermometer function is supported by the ambient temperature sensor, a wiring circuit, the PCM, the PCI data bus, and the Electronics module. If any portion of the ambient temperature sensor circuit fails, the PCM will self-diagnose the circuit. The ambient temperature sensor circuit can also be diagnosed manually. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect to determine the cause. For complete circuit diagrams, refer to the appropriate wiring information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Testing and Inspection > Ambient Temperature Sensor Ambient Temperature Sensor / Switch HVAC: Testing and Inspection Ambient Temperature Sensor 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector. 2. Measure the resistance of the ambient temperature sensor. At room temperature (approx. 68° F), the sensor resistance should be between 10-13 Kilohms. The sensor resistance should be between these two values at 68° F. If the resistance is out of range replace the ambient temperature sensor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Testing and Inspection > Ambient Temperature Sensor > Page 948 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection Ambient Temperature Sensor Circuit 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the Powertrain Control Module (PCM) wire harness connector. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor wire harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the PCM wire harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Remove the jumper wire from the body half of the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the PCM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted sensor return circuit as required. 5. Check for continuity between the ambient temperature sensor signal circuit cavity of the PCM wire harness connector and a good ground. There should be no continuity. If OK, Driver/Vehicle Information Display to determine the cause. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Testing and Inspection > Page 949 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. From behind the front bumper fascia, remove the screw holding the sensor to the radiator closure panel. 3. Disconnect the sensor electrical connector. 4. Remove the sensor from vehicle. INSTALLATION 1. Position the sensor in the vehicle and connect the sensor electrical connector. 2. From behind the front bumper fascia, install the sensor mounting screw. 3. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations Headliner Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 953 Blower Motor Switch: Diagrams Rear Blower Front Control Switch (3 Zone MTC) Rear Blower Rear Control Switch C1 (3 Zone MTC) Rear Blower Rear Control Switch C2 (3 Zone MTC) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 957 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 958 Evaporator Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 959 Evaporator Temperature Sensor / Switch: Description and Operation Evaporator Temperature Sensor - Typical The evaporator temperature sensor used for the manual and automatic temperature control systems on RS models is installed on the top of the HVAC housing behind the instrument panel and measures the air temperature downstream of the evaporator. The sensor is an electrical thermistor in a plastic housing that is inserted into the HVAC housing. Two terminals within the molded plastic connector receptacle on the sensor connect it to the vehicle electrical system through a take out and connector of the HVAC wire harness. Evaporator Temperature Sensor - RG Models The evaporator temperature sensor used for the manual and automatic temperature control systems on RG models is installed on the top of the expansion valve in the right rear corner of the engine compartment and measures the temperature of the evaporator coils. The sensor has a small probe that is Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 960 inserted in a small well in the body of the expansion valve that is filled with a special silicone-based thermal grease. A small molded plastic push-in retainer secures the sensor to a threaded hole in the top surface of the expansion valve. Two terminals within a molded plastic connector receptacle on the sensor connect it to the vehicle electrical system through a take out and connector of the HVAC wire harness. The evaporator temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The evaporator temperature sensor monitors the temperature of the conditioned air once it passes through the A/C evaporator. The evaporator temperature sensor will change its internal resistance in response to the air temperatures it monitors and is connected to the A/C-heater control through sensor ground and signal circuits. As the conditioned air temperature increases, the resistance of the evaporator temperature sensor decreases and the voltage monitored by the A/C-heater control decreases. The external location of the evaporator temperature sensor allows the sensor to be removed or installed without disturbing the refrigerant in the A/C system. The A/C-heater control uses this monitored voltage reading as an indication of the evaporator temperature. The A/C-heater control is programmed to respond to this input by sending electronic messages to the powertrain control module (PCM) over the controller area network (CAN) data bus. The PCM then cycles the A/C compressor clutch as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The evaporator temperature sensor is diagnosed using the DRBIII(R) scan tool. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > RG Models Evaporator Temperature Sensor / Switch: Service and Repair RG Models REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the air cleaner housing from the right side of the engine compartment. 3. Remove the windshield wiper assembly from the vehicle. 4. If equipped with rear A/C, disconnect the liquid and suction lines from the A/C expansion valve. Evaporator Temperature Sensor (RG Models) - Rear A/C Shown 5. Remove the retainer that secures the evaporator temperature sensor to the A/C expansion valve. NOTE: To disconnect the wire harness connector from the evaporator temperature sensor, first push the red retaining ring toward the connector to release the lock, then disconnect the connector from the sensor. 6. Remove the evaporator temperature sensor from the A/C expansion valve and disconnect the wire harness connector. INSTALLATION NOTE: Any grease removed with the evaporator temperature sensor must be replaced. Failure to do so could result in poor A/C performance. 1. Position the evaporator temperature sensor into the right rear corner of the engine compartment. NOTE: To connect the wire harness connector to the evaporator temperature sensor, first connect the connector to the sensor, then pull the red retaining ring toward the sensor. 2. Connect the wire harness connector to the evaporator temperature sensor. 3. Install the evaporator temperature sensor onto the top of the expansion valve with the sensor probe inserted into the well in the expansion valve. 4. Install the temperature sensor retainer. 5. If equipped with rear A/C, connect the liquid and suction lines to the A/C expansion valve and recharge the A/C system. 6. Install the window wiper module. 7. Install the air cleaner housing into the right side of the engine compartment. 8. Reconnect the negative battery cable. 9. Run the HVAC Cool Down test to verify system is operating properly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > RG Models > Page 963 Evaporator Temperature Sensor / Switch: Service and Repair RS Models REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel from the vehicle. Evaporator Temperature Sensor - RS Models 3. Disconnect the wire harness connector from the evaporator temperature sensor located on the top of the HVAC housing. 4. Remove the evaporator temperature sensor from the HVAC housing. INSTALLATION 1. Install the evaporator temperature sensor into the top of the HVAC housing. 2. Connect the wire harness connector to the evaporator temperature sensor. 3. Install the instrument panel. 4. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Diagrams A/C Pressure Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations Right B Pillar Left B Pillar Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 972 Driver Door Passenger Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 973 Right Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 974 Liftgate Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 975 Door Switch: Diagrams Hood Ajar Switch (Export) Left Front Ajar Switch (Base) Left Front Door Lock Motor/Ajar Switch (Except Base) Right Front Door Switch Ajar Switch (Base) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 976 Right Front Door Lock Motor/Ajar Switch (Except Base) Right Sliding Door Lock Motor/Ajar Switch (Manual Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams Back-Up Lamp Switch (MTX) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 988 Brake Light Switch: Connector Locations Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 989 Right Side Kick Panel RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 990 Brake Lamp Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 991 Brake Light Switch: Description and Operation ABS AND BRAKE WARNING INDICATORS The amber ABS warning indicator is located in the instrument cluster. It is used to inform the driver that the antilock function has been turned off. The ABS warning indicator is controlled by the CAB/ABM. The CAB/ABM controls the lamp with a command over the PCI bus. The ABS Warning Indicator will remain lit during every key cycle until a circuit or component fault is repaired and the CAB/ABM no longer detects the fault. After repair of a sensor signal fault or a pump motor fault, the CAB/ABM must sense all four wheels at 25 km/h (15 mph) before it will extinguish the ABS and TCS Indicator. The Instrument Cluster will illuminate the ABS Warning Indicator if it loses communication with the CAB/ABM. The red BRAKE warning indicator is also located in the instrument cluster. It can be activated in several ways. Application of the parking brake or a low fluid signal from the fluid level switch located in the master cylinder reservoir will cause the indicator to come on. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 995 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 996 Steering Column Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 997 Center Instrument Panel Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 998 Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 999 Multi-Function Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description - Turn Signal System Combination Switch: Description and Operation Description - Turn Signal System DESCRIPTION - TURN SIGNAL SYSTEM The turn signals are actuated with a lever on Multi-Function Switch, located on the left side of the steering wheel. The signals are automatically turned off by a canceling cam (two lobes molded to the clock spring mechanism). The cam comes in contact with the cancel actuator on the turn signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. The multi-function switch is a resistive MUX switch that feeds inputs to the BCM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description - Turn Signal System > Page 1002 Combination Switch: Description and Operation Operation - Turn Signal System OPERATION - TURN SIGNAL SYSTEM Lane change signaling is actuated by applying partial turn signal stalk movement toward the direction desired until the indicator lamps flashes in the instrument cluster. When the switch stalk is released the stalk will spring back into the neutral position turning OFF the turn signal. With the ignition switch ON and the turn signal switch stalk actuated left or right, current flows through the: - Multi-function switch - Body Control Module - Integrated Power Module (IPM) - Turn indicator lamp - Front and rear turn signal bulbs. A chime will sound after the vehicle has traveled a distance of approximately 1.0 mile and a speed of 15 mph, with the turn signal ON. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal Combination Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove upper and lower steering column shrouds. 3. Disconnect wire connector from back of multi-function switch. 4. Remove screws holding multi-function switch to steering column adapter collar. 5. Remove the multi-function switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal > Page 1005 Combination Switch: Service and Repair Installation INSTALLATION 1. Position the switch on to the steering column. 2. Install the two retaining screws. 3. Connect the wire harness connector. 4. Install the upper and lower steering column shrouds. 5. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Right B Pillar Left B Pillar Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 1009 Driver Door Passenger Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 1010 Right Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 1011 Liftgate Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 1012 Door Switch: Diagrams Hood Ajar Switch (Export) Left Front Ajar Switch (Base) Left Front Door Lock Motor/Ajar Switch (Except Base) Right Front Door Switch Ajar Switch (Base) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 1013 Right Front Door Lock Motor/Ajar Switch (Except Base) Right Sliding Door Lock Motor/Ajar Switch (Manual Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1017 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1018 Right Side Instrument Panel Lower RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1019 Headlamp Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Specifications Specifications - Battery Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Specifications > Page 1025 Battery Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Specifications > Page 1026 Battery Temperature Sensor: Description and Operation (NGC Vehicles) The PCM incorporates a Battery Temperature Sensor (BTS) on its circuit board. The PCM uses the temperature of the battery area to control the charge system voltage. This temperature, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as temperature around the battery increases. For vehicles with 1.6L engine, there is no physical battery temp sensor in place to detect battery temp. Rather, an algorithm built in PCM is employed to predict battery temp using inlet air temp, vehicle speed, and coolant temp, among other signals. The PCM maintains the optimal output of the generator by monitoring battery voltage and controlling it to a range of 13.5 - 14.7 volts based on battery temperature. The system target voltage is 13.5 - 14.7 volts. However the actual voltage go below this during heavy electrical loads and generator speeds. Also the actual voltage can be lower than the target voltage between the battery and the battery voltage sense circuit, approximately 0.2 - 0.3 volts. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20°F. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Specifications > Page 1027 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor is not serviced separately. If replacement is necessary, the PCM must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 1032 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1033 Camshaft Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1034 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor EGR/CAM Sensor 2.4L The camshaft position sensor for the 3.3/3.8L is mounted in the front of the timing case cover and the camshaft position sensor for the 2.4L is mounted on the end of the cylinder head. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1035 Camshaft Position Sensor The camshaft position sensor provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it (Fig. 2). The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. Camshaft Position Sensor When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1036 Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the sensor. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs on represent which cylinder the flat spot and notches identify, they do not indicate TDC position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1037 NGC Typical Scope Patterns Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1038 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. Air Box Cover 2. Remove the air box cover and inlet tube. Camshaft Position Sensor 3. Disconnect camshaft position sensor electrical connector from the wiring harness connector. 4. Remove bolt holding sensor. 5. Rotate sensor away from block. 6. Pull sensor up out of the chain case cover. Do not pull on the sensor wiring. There is an O-ring on the body of the sensor. The O-ring may make removal difficult. A light tap to top of sensor prior to removal may reduce force needed for removal. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1039 Camshaft Position Sensor And Spacer If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. While holding the sensor in this position, install and tighten the retaining bolt 14 N.m (125 in. lbs.) torque. 4. Connect camshaft position sensor electrical connector to harness connector. 5. Install the air box cover and inlet hose. 6. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations 3.3L & 3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 1047 Crankshaft Position Sensor: Connector Locations Starter Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 1048 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1049 Crankshaft Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1050 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR Crankshaft Sensor 2.4L The 2.4L crankshaft sensor is located on the rear of the engine near the accessory drive belt. The 3.3L/3.8L crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1051 Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1052 NGC Typical Scope Patterns Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Pump Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1056 Fuel Level Sensor: Service and Repair Fuel Pump/Level Sensor Electrical Connector Wire Terminal Locking Finger Removing Wires From Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1057 Loosening Level Sensor Level Sensor Removal/Installation Groove In Back Side Of Level Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1058 Installation Channel Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1063 Intake Air Temperature Sensor: Connector Locations Inlet Air Sensors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 1064 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1065 Inlet Air Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1066 Intake Air Temperature Sensor: Description and Operation 3.3/3.8L IAT Sensor The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation The knock sensor threads into the cylinder block. The knock sensor is designed to detect engine vibration that is caused by detonation. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives as an input the knock sensor voltage signal. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except WOT. The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1073 Manifold Absolute Pressure Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1074 Manifold Pressure/Vacuum Sensor: Description and Operation Map Sensor 2.4L Map Sensor 3.3/3.8L The MAP sensor mounts to the intake manifold The sensor is connects electrically to the PCM The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a volt-age signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5 V and full scale is 4.5 V. For a pressure swing of 0 - 15 psi the voltage changes 4.O V. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key on. The difference between current and what it was at key on is manifold vacuum. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1075 During key On (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in you work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key On the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC 1 transmissions only via the PCI bus) - Idle speed - Decel fuel shutoff The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 29.92 in Hg. For every 100 feet of altitude barometric pressure drops .10 in. Hg. If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1076 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. Map Sensor 3.3/3.8L 2. Remove vacuum hose and mounting screws from manifold absolute pressure (MAP) sensor. 3. Disconnect electrical connector from sensor. Remove sensor. INSTALLATION 1. Install sensor. 2. Install screws and tighten to PLASTIC MANIFOLD 1.7 N.m (15 in. lbs.) ALUMINUM MANIFOLD 3.3 N.m (30 in. lbs.). 3. Connect the electrical connector to the sensor. Install vacuum hose. 4. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Oxygen Sensors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 1080 3.3-3.8 Liter Engine Front Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 1081 Engine Pressure Switch (GAS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC P0135 Set NUMBER: 18-010-05 REV. A GROUP: Vehicle Performance DATE: March 4, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-010-05, DATED FEBRUARY 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN UPDATED VEHICLE BUILD DATE. THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD APRIL, 2005. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DIG) P0135 - 02 Sensor 1/1 Heater Performance OVERVIEW: This bulletin involves verifying the proper 1/1 02 Sensor is installed on the vehicle and reprogramming the Powertrain Control Module with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager NOTE: **This bulletin applies to 2005 CS and RS vehicles equipped with a 3.8L engine (sales code EGH) built on and between July 8, 2004 (MDH 0708XX) and March 2, 2005 (MDH 0302XX). 2005 RS vehicles equipped with a 3.3L engine (sales code EGA, EGM and EGH) built on and between July 8, 2004 (MDH 0708XX) and October 29, 2004 (MDH 1029XX).** SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by the following Diagnostic Trouble Codes (DTC's): P0135 - 02 Sensor 1/1 Heater Performance DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than the one listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. Verify that the correct 02 Sensor is installed on the vehicle. Refer to Service Bulletin 08-008-05. Installing an incorrect 1/1 02 sensor will cause a MIL illumination for DTC P0135 - 02 Sensor 1/1 Heater Performance to be set. If the vehicle operator describes or experiences the Symptom/Condition and the correct 1/1 02 sensor is installed on the vehicle, perform the Repair Procedure. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 1090 SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 1091 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 08-008-05 > Feb > 05 > Engine Controls - MIL ON/DTC P0135 (O2 Sensor) Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC P0135 (O2 Sensor) NUMBER: 08-008-05 GROUP: Electrical DATE: February 4, 2005 SUBJECT: 1/1 02 Sensor Usage MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager 2005 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to 2005 CS vehicles equipped with a 3.8L engine (sales code EGH), 2005 RS or 2005 RG vehicles equipped with a 3.313.8L engine (sales code EGA, EGM and EGH). DISCUSSION: A new 1/1 02 sensor (PN 56029085AA) has been introduced on the 3.313.8L engines for the 2005 RS/RG and CS vehicles built after July 8, 2004 (MDH 0708XX). Installing an incorrect 1/1 02 sensor will cause a MIL illumination for DTC P0135 - 02 Sensor 1/1 Heater Performance to be set. The operation of the new 02 sensor has also changed. The new 1/1 02 sensor runs at 100% duty cycle all the time because the resistance of the heater is higher. Monitoring the 1/1 02 sensor with the DRBIII(R) while the vehicle is in the service bay will show 100% duty cycle, which is normal for this new sensor. 2005 Model Year 1/1 02 Sensor Usage POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0135 Set NUMBER: 18-010-05 REV. A GROUP: Vehicle Performance DATE: March 4, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-010-05, DATED FEBRUARY 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN UPDATED VEHICLE BUILD DATE. THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD APRIL, 2005. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DIG) P0135 - 02 Sensor 1/1 Heater Performance OVERVIEW: This bulletin involves verifying the proper 1/1 02 Sensor is installed on the vehicle and reprogramming the Powertrain Control Module with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager NOTE: **This bulletin applies to 2005 CS and RS vehicles equipped with a 3.8L engine (sales code EGH) built on and between July 8, 2004 (MDH 0708XX) and March 2, 2005 (MDH 0302XX). 2005 RS vehicles equipped with a 3.3L engine (sales code EGA, EGM and EGH) built on and between July 8, 2004 (MDH 0708XX) and October 29, 2004 (MDH 1029XX).** SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by the following Diagnostic Trouble Codes (DTC's): P0135 - 02 Sensor 1/1 Heater Performance DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than the one listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. Verify that the correct 02 Sensor is installed on the vehicle. Refer to Service Bulletin 08-008-05. Installing an incorrect 1/1 02 sensor will cause a MIL illumination for DTC P0135 - 02 Sensor 1/1 Heater Performance to be set. If the vehicle operator describes or experiences the Symptom/Condition and the correct 1/1 02 sensor is installed on the vehicle, perform the Repair Procedure. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 1101 SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 1102 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 08-008-05 > Feb > 05 > Engine Controls - MIL ON/DTC P0135 (O2 Sensor) Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0135 (O2 Sensor) NUMBER: 08-008-05 GROUP: Electrical DATE: February 4, 2005 SUBJECT: 1/1 02 Sensor Usage MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager 2005 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to 2005 CS vehicles equipped with a 3.8L engine (sales code EGH), 2005 RS or 2005 RG vehicles equipped with a 3.313.8L engine (sales code EGA, EGM and EGH). DISCUSSION: A new 1/1 02 sensor (PN 56029085AA) has been introduced on the 3.313.8L engines for the 2005 RS/RG and CS vehicles built after July 8, 2004 (MDH 0708XX). Installing an incorrect 1/1 02 sensor will cause a MIL illumination for DTC P0135 - 02 Sensor 1/1 Heater Performance to be set. The operation of the new 02 sensor has also changed. The new 1/1 02 sensor runs at 100% duty cycle all the time because the resistance of the heater is higher. Monitoring the 1/1 02 sensor with the DRBIII(R) while the vehicle is in the service bay will show 100% duty cycle, which is normal for this new sensor. 2005 Model Year 1/1 02 Sensor Usage POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1109 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1110 Oxygen Sensor: Connector Locations Oxygen Sensors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1111 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 1112 3.3-3.8 Liter Engine Front Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1113 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream (3.3L/3.8L) Oxygen Sensor 1/2 Downstream (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1114 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1115 Oxygen Sensor: Description and Operation O2 Sensor Upstream 1/1 - 2.4L O2 Sensor Upstream 1/1 - 3.3/3.8L The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1116 O2 Sensor Downstream 1/2 - 2.4/3.3/3.8L The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic convertor. A separate upstream and downstream grounds are used on the NGC vehicles (4 Cyl). As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor, one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The 02 sensors produce a constant 2.5 volts on NGC vehicles, depending upon the oxygen content of the exhaust gas. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produces a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2 sensors input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. NGC Controller - Has a common ground for the heater in the 02S. 12 volts is supplied to the heater in the 02S by the NGC controller. Both the upstream and downstream 02 sensors for NGC are pulse width modulation (PWM). NOTE: When replacing an 02 Sensor, the PCM RAM memory must be cleared, either by disconnecting the PCM C-1 connector or momentarily disconnecting the Battery negative terminal. The NGC learns the characteristics of each O2 heater element and these old values should be cleared when installing a new 02 sensor. The customer may experience driveability issues if this is not performed. UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 2.5 to 3.5 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 2.5 volt. When there is a lesser amount of oxygen present (rich air/fuel mixture) the sensor produces a voltage as high as 3.5 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1117 The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. DOWNSTREAM OXYGEN SENSOR The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. Also used to establish the upstream 02 goal voltage (switching point). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor REMOVAL - DOWNSTREAM 1/2 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Downstream Oxygen Sensor (1/2) 3. Disconnect the electrical connector. Downstream 2/1 O2 Sensor 4. Use a socket such as the Snap-On(R) YA8875 or equivalent to remove the sensor. 5. When the sensor is removed, the threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using the original sensor, coat the threads with Loctite 771 - 64 anti-seize compound or equivalent. INSTALLATION - DOWNSTREAM 2/1 The O2S is located on the side of the catalytic converter. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 1120 Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install sensor and tighten to 27 N.m (20 ft. lbs.). 2. Connect the electrical connector. 3. Lower vehicle. 4. Install the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 1121 Oxygen Sensor: Service and Repair Upstream Sensor REMOVAL - UPSTREAM 1/1 1. Remove battery, refer to the Battery section for more information. 2. Remove the battery tray, refer to the Battery section for more information. 3. Disconnect the speed control vacuum harness from servo. 4. Disconnect the electrical connector from servo. 5. Remove the speed control servo and bracket and reposition. O2 Sensor 1/1 6. Use a socket such as the Snap-On(R) YA8875 or equivalent to remove the sensor. 7. When the sensor is removed, the threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using the original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. INSTALLATION - UPSTREAM 1/1 The engines uses two heated oxygen sensors. 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771 - 64 or equivalent. New sensors have compound on the threads and do not require an additional coating. 2. Install sensor and tighten to 27 N.m (20 ft. lbs.). 3. Connect the electrical connector for the O2 sensor and install onto bracket. 4. Connect the electrical connector for the speed control servo. 5. Install the speed control servo and bracket refer to the Speed Control Servo for more information. 6. Connect the speed control vacuum harness to servo. 7. Install the battery tray, refer to the Battery section for more information. 8. Install battery, refer to the Battery section for more information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 1122 Oxygen Sensor: Tools and Equipment O2S (Oxygen Sensor) Removal/Install - C 4907 O2S (Oxygen Sensor) Removal/Install - 8439 O2S (Oxygen Sensor) Removal/Installation C 4907 O2S (Oxygen Sensor) Removal/Installer - 8439 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 1127 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1128 Throttle Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1129 Throttle Position Sensor: Description and Operation Throttle Position Sensor 2.4L Engine Throttle Position Sensor 3.3/3.8L Engine The throttle position sensor mounts to the side of the throttle body.The sensor connects to the throttle blade shaft. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 1130 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the electrical connector from the Inlet Air Temperature sensor. 3. Remove the air cleaner box lid. Remove hose from throttle body. 4. Disconnect the electrical connector at TPS. 5. Disconnect the electrical connector at IAC. 6. Remove the throttle and speed control cables from throttle body. 7. Remove 3 mounting bolts from throttle body. 8. Remove throttle body. 9. Disconnect the purge vacuum line from the throttle body. 10. Remove TPS from throttle body. INSTALLATION 1. Install TPS to throttle body. 2. Disconnect the purge vacuum line from the throttle body. 3. Install throttle body. 4. Install 3 mounting bolts from throttle body. Tighten bolts. 5. Install the throttle and speed control cables to throttle body. 6. Connect the electrical connector at TPS. 7. Connect the electrical connector at IAC. 8. Install the air cleaner box lid. Install hose to throttle body. 9. Install the electrical connector to the Inlet Air Temperature sensor. 10. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR Sensor, Transmission Range Sensor ...................................................................................................................................................... 5 Nm (45 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 1136 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1137 Transmission Range Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 337). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 338). OPERATION The Transmission Range Sensor (TRS) (Fig. 337) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 1140 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 338) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 1141 Transmission Position Switch/Sensor: Description and Operation 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 303). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM/TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 304). OPERATION The Transmission Range Sensor (TRS) (Fig. 303) communicates Shift Lever Position (SLP) to the PCM/TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the PCM/TCM receives from four sense circuits. The PCM/TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the PCM/TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 1142 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 304) that the PCM/TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the PCM/TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the PCM/TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 1143 Transmission Position Switch/Sensor: Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle Transmission Position Switch/Sensor: Service and Repair 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 305). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 305) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 1146 Transmission Position Switch/Sensor: Service and Repair 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 339). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 339) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 1147 Transmission Position Switch/Sensor: Service and Repair 41TE REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 343). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 343) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation Vehicle Speed Sensor: Description and Operation Vehicle Speed and Distance Description The PCM receives a signal from the transaxle output speed sensor over the bus communication line. Operation The 4 speed automatic transaxle output speed sensor supplies the speed input to the PCM. The PCM determines acceleration rates. The speed control software in the PCM uses vehicle speed and acceleration to control to the set speed. For more information of the Output Speed Sensor please refer to: See: Sensors and Switches Transmission and Drivetrain/Sensors and Switches - A/T/Transmission Speed Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 1156 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1157 Throttle Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1158 Throttle Position Sensor: Description and Operation Throttle Position Sensor 2.4L Engine Throttle Position Sensor 3.3/3.8L Engine The throttle position sensor mounts to the side of the throttle body.The sensor connects to the throttle blade shaft. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 1159 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the electrical connector from the Inlet Air Temperature sensor. 3. Remove the air cleaner box lid. Remove hose from throttle body. 4. Disconnect the electrical connector at TPS. 5. Disconnect the electrical connector at IAC. 6. Remove the throttle and speed control cables from throttle body. 7. Remove 3 mounting bolts from throttle body. 8. Remove throttle body. 9. Disconnect the purge vacuum line from the throttle body. 10. Remove TPS from throttle body. INSTALLATION 1. Install TPS to throttle body. 2. Disconnect the purge vacuum line from the throttle body. 3. Install throttle body. 4. Install 3 mounting bolts from throttle body. Tighten bolts. 5. Install the throttle and speed control cables to throttle body. 6. Connect the electrical connector at TPS. 7. Connect the electrical connector at IAC. 8. Install the air cleaner box lid. Install hose to throttle body. 9. Install the electrical connector to the Inlet Air Temperature sensor. 10. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 1165 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1166 Camshaft Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1167 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor EGR/CAM Sensor 2.4L The camshaft position sensor for the 3.3/3.8L is mounted in the front of the timing case cover and the camshaft position sensor for the 2.4L is mounted on the end of the cylinder head. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1168 Camshaft Position Sensor The camshaft position sensor provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it (Fig. 2). The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. Camshaft Position Sensor When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1169 Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the sensor. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs on represent which cylinder the flat spot and notches identify, they do not indicate TDC position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1170 NGC Typical Scope Patterns Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1171 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. Air Box Cover 2. Remove the air box cover and inlet tube. Camshaft Position Sensor 3. Disconnect camshaft position sensor electrical connector from the wiring harness connector. 4. Remove bolt holding sensor. 5. Rotate sensor away from block. 6. Pull sensor up out of the chain case cover. Do not pull on the sensor wiring. There is an O-ring on the body of the sensor. The O-ring may make removal difficult. A light tap to top of sensor prior to removal may reduce force needed for removal. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1172 Camshaft Position Sensor And Spacer If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. While holding the sensor in this position, install and tighten the retaining bolt 14 N.m (125 in. lbs.) torque. 4. Connect camshaft position sensor electrical connector to harness connector. 5. Install the air box cover and inlet hose. 6. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations 3.3L & 3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 1177 Crankshaft Position Sensor: Connector Locations Starter Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 1178 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1179 Crankshaft Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1180 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR Crankshaft Sensor 2.4L The 2.4L crankshaft sensor is located on the rear of the engine near the accessory drive belt. The 3.3L/3.8L crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1181 Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1182 NGC Typical Scope Patterns Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation KEY/LOCK CYLINDER DESCRIPTION The lock cylinder is inserted in the end of the housing opposite the ignition switch. OPERATION The ignition key rotates the cylinder to 5 different detents (Fig. 30): Accessory - Off (lock) - Unlock - On/Run - Start Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 1187 Ignition Switch Lock Cylinder: Service and Repair Key/Lock Cylinder REMOVAL 1. Disconnect negative cable from battery. 2. Remove steering column cover retaining screws. 3. Remove screws holding steering column shrouds and remove lower shroud. 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab on the bottom of the lock housing and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position (Fig. 31). 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6. Install steering column cover. 7. Connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation The knock sensor threads into the cylinder block. The knock sensor is designed to detect engine vibration that is caused by detonation. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives as an input the knock sensor voltage signal. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except WOT. The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement Technical Service Bulletin # J38 Date: 100420 Campaign - Front Air Bag Sensor Replacement April 2010 Dealer Service Instructions for: Customer Satisfaction Notification J38 Supplemental Front Airbag Sensors Models 2005-2006 (RS) Dodge Caravan, Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles built from January 19, 2005 through April 5, 2006 (MDH 011900 through 040500). IMPORTANT: Many of the vehicles within the above build period have already been repaired according to our warranty records, and therefore, have been excluded from this notification. Only the above vehicles originally sold or currently registered in certain states are involved. See the "Owner Notification and Service Scheduling" section for a list of states involved in this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The supplemental front airbag sensors on about 310,000 of the above vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Repair The right and left supplemental front airbag sensors must be replaced and the sensor wiring harness connectors must be inspected and replaced, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1200 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1201 Parts Information Special Tools The following special tools may be required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1202 Use the labor operation numbers and time allowances as shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicableable. Only vehicles originally sold or currently registered in the following states are involved in this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1203 To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure A. Supplemental Front Airbag Sensor Replacement 1. Lower the driver's window completely. 2. Open the hood. 3. Disconnect and isolate the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Raise the vehicle on a suitable hoist. 5. Disconnect the wiring harness connector to the right and left supplemental front airbag sensor. The sensors are located on the outside of the right and left frame rails at the radiator lower crossmember (Figure 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1204 6. Remove the right and left supplemental front airbag sensors and discard the sensors and retaining bolts. CAUTION: If the retaining bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose from the radiator lower crossmember. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensor retaining bolts, continue with Step 9. 7. Use the following procedure, if required, to replace a spun riv-nut: a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps. b. Remove the four screws (two each side) that secure the left and right wheelhouse splash shield to the front fascia. c. Remove the right and left side fascia-to-fender bolts. d. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. e. Partially lower the vehicle. f. Remove the right and left fascia bolts from the upper radiator crossmember (Figure 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1205 g. Pull the wheelhouse shield back from the front fascia and remove the right and left nuts holding the front fascia to the front lip of the fender (Figure 3). h. Carefully remove the front fascia and set it aside. CAUTION: Be careful not to scratch the painted surfaces of the front fascia and front fenders. i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard. j. Using a cut-off wheel, remove the head of the airbag sensor mounting bolt. k. Remove and discard the supplemental front airbag sensor bushing. l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool. NOTE: Be sure to completely remove the riv-nut from the lower radiator crossmember. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1206 n. Pre-assemble the new riv-nut by installing the installation nut and the riv-nut onto the installation bolt as shown in Figure 4. o. Insert the new riv-nut-bolt/nut assembly into the original riv-nut hole in the lower radiator crossmember. p. Using a 10mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5). q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut. r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely). 8. For vehicles that had the front fascia removed, use the following procedure to install the front fascia: a. Position the front fascia onto the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1207 b. Install the right and left upper fascia bolts finger tight (Figure 6). c. Install the right and left nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m). d. Install and tighten the two fascia-to-fender bolts. e. Install the four screws (two on each side) that secure the right and left wheelhouse shield to the front fascia. f. Using new push pins if necessary, install the air dam to the lower radiator crossmember. g. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps. h. Continue with Step 9. 9. Inspect the right and left supplemental front airbag sensor wiring connectors. > If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B. Airbag Sensor Harness Connector Replacement. > If there is no corrosion on either terminal of the harness connectors, continue with Section C. Supplemental Front Airbag Sensor Installation. B. Airbag Sensor Harness Connector(s) Replacement NOTE: Only those harness connector(s) that exhibit terminal corrosion, as described in Section A, require replacement. 1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector. 2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness. 3. Remove 1/2 inch (13 mm) of insulation from each wire. 4. Cut the new harness connector wires so that the final length is equal to the old harness. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1208 5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire. 6. Slide one piece of heat shrink tubing onto each of the harness connector wires. 7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just enough to hold the splice band in place. 8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows: > For the right (passenger side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the purple (w/blue tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the white (w/blue tracer) wire on the body wiring harness. > For the left (driver's side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the blue (w/purple tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the blue (w/white tracer) wire on the body wiring harness. CAUTION: Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band. 10. Crimp the splice band and wires together by squeezing the crimping tool handles. NOTE: The tool will release once the proper crimping force has been achieved. 11. Solder the connection together using only rosin core type solder. CAUTION: DO NOT use acid core solder. 12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing. CAUTION: Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure. 13. Continue with Section C. Supplemental Front Airbag Sensor Installation. C. Supplemental Front Airbag Sensor Installation 1. Clean the supplemental front airbag sensor mounting surface for both sensors. 2. Install the new supplemental front airbag sensors using the fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091. NOTE: Use the bolts with a blue thread locker patch on the threads. Discard the pointed self tapping screws and flat washers. They will not be used in this repair procedure. 3. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. 4. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1209 5. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector (Figure 7). NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor wiring harness connector. 6. Connect the wiring harness connectors to the right and left supplemental front airbag sensors. 7. Lower the vehicle from the hoist. 8. For vehicles that had the Fascia removed, tighten the upper fascia bolts to 50 in. lbs. (5 N.m). 9. Connect the negative battery cable to the battery. 10. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "RUN" position. Wait 10 seconds: > If the airbag warning light is not illuminated, the repair has been completed. No further action is required, return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 11 to clear the Diagnostic Trouble Codes (DTC's). 11. Use the following procedure to clear DTC's: a. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. b. Turn the ignition key to the "RUN" position. c. Press the "YES" button after the DRBIII powers up. d. Select "DRBIII STANDALONE" and press "ENTER". e. Select "1998-2007 DIAGNOSTICS" and press "ENTER". f. Select "ALL" and press "ENTER". g. Select "PASSIVE RESTRAINT" and press "ENTER". h. Select "AIRBAG" and press "ENTER". i. Select "READ DTC's" and press "ENTER". j. Select "STORED" and press "ENTER". k. Press the "PAGE BACK" button and follow the screen prompts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1210 l. Disconnect and remove the DRBIII from the vehicle and return the vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement Technical Service Bulletin # G09 Date: 070601 Recall - Front Air Bag Impact Sensor Replacement June 2007 Dealer Service Instructions for: Customer Satisfaction Notification G09 Supplemental Front Airbag Sensors Models 2005 (RS) Dodge Caravan, Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles built at the Windsor Assembly plant ("R" in the 11th VIN position) through February 3, 2005 (MDH 020323) and the St. Louis Assembly plant ("B" in the 11th VIN position) through January 19, 2005 (MDH 011923). IMPORTANT: Many of the vehicles within the above build period have already been repaired according to our warranty records, and therefore, have been excluded from this notification. Only the above vehicles originally sold or currently registered in certain states are involved. See the "Owner Notification and Service Scheduling" section for a list of states involved in this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair service on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The supplemental front airbag sensors on about 263,000 of the above vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Repair The right and left supplemental front airbag sensors must be replaced and the sensor harness connectors must be inspected and replaced, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1215 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1216 Parts Information Special Tools The special tools may be required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record repair service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1217 Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Attached to each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Only vehicles originally sold or currently registered in the following states are involved in this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Supplemental Front Airbag Sensor Replacement 1. Lower the driver¡C■s window completely. 2. Open the hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1218 3. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Raise the vehicle on a suitable hoist. 5. Disconnect the harness connector to the right and left supplemental front airbag sensor (Figure 1). 6. Remove the right and left supplemental front airbag sensors and discard the bolts and sensors. NOTE: There are two types of bolts used to fasten the sensors to the radiator crossmember; an M7 self tapping bolt or an M6 bolt used with a riv-nut. If the bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensors, continue with Step 8. 7. Replaced a spun riv-nut as follows: NOTE: The following procedure is applicable for vehicle built at the Windsor Assembly Plant after May 24, 2004 or the St. Louis Assembly Plant after June 28, 2004. Very few vehicles are expected to require riv-nut replacement. a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps. b. Remove the two screws that secure the left and right wheelhouse splash shield to the front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1219 c Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. d. Partially lower the vehicle. e. Remove the right and left fascia upper bolts from the upper radiator crossmember (Figure 2). f. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Figure 3) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1220 g. Remove the two vertical screws holding the front fascia to the front fender. h. Carefully remove the front fascia and set it aside. CAUTION: Be careful not to scratch the painted surfaces of the front fascia and the front fenders. i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard. j. Using a cut-off wheel, cut off the head of the airbag sensor mounting bolt. k. Remove and discard the supplemental front airbag sensor bushing. l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool. NOTE: Be sure to completely remove the riv-nut from the lower radiator crossmember. n. Pre-assemble the new riv-nut by installing the M6 nut and the riv-nut onto the M6 bolt as shown in Figure 4. o. Insert the riv-nut-bolt/nut assembly into the body sheet metal hole. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1221 p. Using a 10 mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5). q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut. r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely). s. Clean the supplemental front airbag sensor mounting surface for both sensors. t. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091: > For sensors fastened with self tapping bolts: a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6. b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts. c. Tightening the self tapping bolts to 60 in.lbs. (7 N.m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1222 > For sensors fastened with M6 bolts and riv-nuts: a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). u. Inspect the right and left supplemental front airbag sensor wiring connectors. If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B Harness Connector Replacement. v. Position the front fascia onto the vehicle. w. Install the right and left upper bolts fascia bolts and tighten to 50 in. lbs. (5 N.m). x. Install the right and left horizontal nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m). y. Install and tighten the two vertical screws that secure the front fascia to the front fenders. z. Install the two screws that secure the right and left wheelhouse shield to the front fascia. aa. Using new push pins if necessary, install the air dam to the lower radiator crossmember. ab. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps. ac. Continue with Step 10. 8. Clean the supplemental front airbag sensor mounting surface for both sensors. 9. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091: > For sensors fastened with self tapping bolts: a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6. b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts. c. Tightening the self tapping bolts to 60 in. lbs. (7 N.m). > For sensors fastened with M6 bolts and riv-nuts: a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). 10. Inspect the right and left supplemental front airbag sensor wiring connectors. If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B - Harness Connector Replacement. 11. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector. NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector. 12. Connect harness connectors to the right and left supplemental front airbag sensors. 13. Lower the vehicle. 14. Connect the negative battery cable to the battery. 15. Stand next to the vehicle with the driver¡C■s door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "ON" position. Wait 10 seconds: > If the airbag warning light is not illuminated the repair has been completed. Return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1223 continue with Step 16 to clear the sensor DTC. 16. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. 17. Turn the ignition key to the "ON" position. 18. Press the "YES" button when the DRBIII powers up. 19. Select "DRBIII STANDALONE" and press "ENTER". 20. Select "1997-2007 DIAGNOSTICS" and press "ENTER". 21. Select "ALL" and press "ENTER" 22. Select "PASSIVE RESTRAINT" and press "ENTER". 23. Select "CLEAR DTCS". 24. Disconnect and remove the DRBIII from the vehicle. B. Airbag Sensor Harness Connector Replacement NOTE: Only those harness connectors that exhibit terminal corrosion, as described in Section A, require replacement. 1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector. 2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness. 3. Remove 1/2 inch (13 mm) of insulation from each wire. 4. Cut the new harness connector wires so that the final length is equal to the old harness. 5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire. 6. Slide one piece of heat shrink tubing onto each of the harness connector wires. 7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just the tool just CAUTION: The crimp jaw must be installed in the crimp tool frame as shown in Figure 7. The crimp jaw wire gauge numbers must be on the same side. When installing the crimp jaw into the tool frame, orient the upper die with the arrow pointed "up" and the lower die with the arrow pointed forward. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1224 8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows: > For the right (passenger side) supplemental front airbag sensor, match the new harness connector wire colors to the same color wire on the existing body wire harness. > For the left (driver's side) supplemental front airbag sensor, match the new harness connector wire colors to same tracer (stripe) color wire on the existing body wire harness. CAUTION: Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. warning lamp. 9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band (Figure 8). 10. Crimp the splice band and wires together by squeezing the crimping tool handles. The tool will release once the proper crimping force has been achieved (Figure 8). 11. Solder the connection together using only rosin-core type solder (Figure. 9). CAUTION: DO NOT use acid core solder. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1225 12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Figure 10). CAUTION: Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure. 13. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector. NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector. 14. Connect harness connectors to the right and left supplemental front airbag sensors. 15. For vehicles with the front fascia removed: a. Position the front fascia onto the vehicle. b. Install the right and left upper fascia bolts and tighten to 50 in. lbs. (5 N.m). c. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender. Tighten the nuts to 60 in. lbs. (7 N.m). d. Install and tighten the two vertical screws that secure the front fascia to the front fenders. e. Install the two screws that secure the right and left wheelhouse shield to the front fascia. f. Using new push pins if necessary, securing the air dam to the lower radiator crossmember. g. For vehicles with fog lamps, connect the electrical harness connectors to the right and left fog lamps. 16. Lower the vehicle. 17. Connect the negative battery cable to the battery. 18. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel, and turn the ignition key to the "ON" position. Wait 10 seconds: > If the airbag warning light is not illuminated, the repair has been completed. Return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 19 to clear the sensor DTC. 19. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. 20. Turn the ignition key to the "ON" position. 21. Press the "YES" button when the DRBIII powers up. 22. Select "DRBIII STANDALONE" and press "ENTER". 23. Select "1997-2007 DIAGNOSTICS" and press "ENTER". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1226 24. Select "ALL" and press "ENTER". 25. Select "PASSIVE RESTRAINT" and press "ENTER". 26. Select "CLEAR DTCS". 27. Disconnect and remove the DRBIII from the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > NHTSA07V192000 > May > 07 > Recall 07V191000: Air Bag Impact Sensor Replacement Impact Sensor: Recalls Recall 07V191000: Air Bag Impact Sensor Replacement MAKE/MODELS: MODEL/BUILD YEARS: Chrysler/Town & Country 2005 Dodge/Caravan 2005 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V192000 MFR'S REPORT DATE: May 01, 2007 COMPONENT: Air Bags: Frontal: Sensor/Control Module POTENTIAL NUMBER OF UNITS AFFECTED: 270958 SUMMARY: Certain minivans are being recalled that were originally sold in or currently registered in the 27 states plus The District of Columbia that use greater amounts of salt for Winter road deicing. The Up-Front (UF) air bag sensors that contain brass bushings installed in these vehicles may corrode and crack allowing water to enter the sensor. These sensors provide enhanced air bag performance in certain types of frontal crashes. CONSEQUENCE: In one of these crashes, with one or both of the vehicle the vehicle's UF sensors inoperative, the occupants will not benefit from the enhanced air bag protection that these sensors would provide. REMEDY: For vehicles registered in the recall states, dealers will replace the original UF air bag sensors with ones with greater corrosion resistance. Vehicles registered in other states will obtain a lifetime free replacement of any UF sensor that fails. The campaign is expected to begin during July 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler's campaign Nos. G09/X16. DaimlerChrysler has not decided that this is a defect related to motor vehicle safety. However, it has informed NHTSA that it will provide the modifications described above free of charge. Customers also may contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline aT 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set Technical Service Bulletin # 08-020-07 Date: 070713 Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set NUMBER: 08-020-07 GROUP: Electrical DATE: July 13, 2007 SUBJECT: Supplemental Front Air Bag Sensor Replacement (Lifetime Warranty) OVERVIEW: This bulletin involves verifying that a right and/or left front impact supplemental airbag sensor(s) Diagnostic Trouble Code (DTC) exists in the Occupant Restraint Control Module (ORG). If DTC's exist, the right and left supplemental front airbag sensors must be replaced and the sensor harness connectors must be inspected for corrosion and replaced if necessary. NOTE: Technicians performing this procedure for the first time should fully familiarize themselves with the steps and procedures listed in this Service Bulletin before proceeding. MODELS: 2005 (RG) Chrysler Voyager 2005 (RS) Town & Country/Caravan/Voyager NOTE: This bulletin applies to vehicles built at the Windsor Assembly Plant ("R" in the 11th VIN position) through February 3, 2005 (MDH 020323), the St. Louis Assembly plant ("B" in the 11th VIN position) through January 19, 2005 (MDH 011923) or the Styler Assembly plant ("Y" in the 11th VIN position) through January 04, 2005 (MDH 010423). DISCUSSION: The supplemental front airbag sensors may crack under certain conditions and allow water to enter into the sensor(s). These sensors were added to enhance the performance of the vehicles airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. DIAGNOSIS: If the vehicle operator experiences air bag warning lamp illumination with any of the following DTC's; NO RIGHT FRONT IMPACT SENSOR COMMUNICATION / RIGHT FRONT IMPACT SENSOR INTERNAL 1/ NO LEFT FRONT IMPACT SENSOR COMMUNICATION or LEFT FRONT IMPACT SENSOR INTERNAL 1, perform the Repair Procedure. If the air bag warning lamp is on due to other DTC's, this bulletin does not apply. Refer to diagnostic procedures available in DealerCONNECT >>> TechCONNECT under: Diagnostics > 7.2 AIRBAG for further information. NOTE: Vehicles that are included in Customer Satisfaction Notification G09 are not included in this Service Bulletin and must be repaired under the procedures and labor operation numbers listed within G09. Vehicles not included in G09 must use this Service Bulletin for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1236 PARTS REQUIRED: NOTE: Connectors, Self-Tapping Screws and Riv-nuts will be used on an "as needed" basis. SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. NOTE: Vehicles included in this Service Bulletin have a lifetime warranty on supplemental front airbag sensors, mounting hardware and sensor electrical connectors as described in this Service Bulletin. See Warranty Bulletin D-07-19 for details associated with the lifetime warranty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1237 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Lower the driver's side window. 2. Disconnect the Negative Battery Cable. 3. Refer to the detailed removal procedures available in DealerCONNECT >>> TechCONNECT under: Service Information Tab >>> Group 8, Electrical >>> Restraints >>> Impact Sensor >>> Removal. 4. When removing the attaching bolts for the sensor, does any of the bolts spin freely and not come out? (See NOTES below). a. Yes >>> Proceed to Step # 5 b. No >>> Proceed to Step # 22 NOTE: There are 2 types of bolts used to fasten the sensors to the radiator crossmember; a M7 self tapping bolt or a M6 bolt used with a riv-nut. If the bolt spins and cannot be removed, the riv-nut has broken loose. If the riv-nut spins and the bolt cannot be removed, proceed to next step to replace riv-nut(s). If no issue with the riv-nut is found, proceed to Step # 22. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1238 NOTE: The riv-nut procedure is applicable for vehicles built at the Windsor Assembly plant after May 24, 2004 or the St. Louis Assembly plant after June 28, 2004 or the Styler Assembly plant after June 28, 2004. Very few vehicles will require riv-nut replacement. 5. If the vehicle equipped with fog lamps, disconnect electrical harness connectors from both fog lamps. 6. Remove the 2 screws that secure the left and right wheelhouse splash shield to the front fascia. 7. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. 8. Remove the right and left fascia upper bolts from the upper radiator crossmember. (Fig 2) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1239 9. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Fig. 3) 10. Remove 2 vertical screws holding the front fascia to the front fender. 11. Carefully remove the front fascia and set aside. CAUTION: Care should be used not to damage painted surfaces. 12. Break the front air bag sensor using a suitable tool. Remove broken sensor pieces. 13. Using a powered cut-off wheel, remove the head of the sensor mounting bolt. 14. Remove sensor bushing from bolt. 15. Using a powered cut-off wheel, cut the bolt and lip of the riv-nut flush with sheet metal. 16. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. 17. Remove the old riv-nut through the access hole in the crossmember using a magnetic tool. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1240 18. Preassemble the new riv-nut, p/n CBX2G093 by installing the M6 nut, and the riv-nut onto the bolt, as shown in (Fig. 4). 19. Insert the riv-nut and bolt assembly into the original mounting hole. 20. Using a 10 mm crows foot, tighten the installation nut to 9 Nm, (80 in. lb) while holding the installation bolt stationary (Fig. 5). 21. Repeat Step # 12 through Step # 20 for remaining riv-nut(s) that have broken loose and spin freely. 22. Clean the mounting surface for both sensors. 23. Install the new sensors using the appropriate fasteners; Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1241 a. For sensors fastened with self-tapping bolts. Proceed to >>> # 24. b. For sensors fastened with M6 bolts and riv-nuts. Proceed to >>> Step # 26. 24. For self-tapping fastener installation; preassemble both air bag sensors with self-tapping bolts and washers (Fig. 6). 25. Position the sensors on the vehicle and tighten each self-tapping bolt into the mounting hole about 5 turns to cut new threads for the larger M7 bolt. Tighten to 7 Nm, (60 in. lb). Proceed to Step # 27. 26. For M6 bolt and riv-nut fastener installation; hand start both bolts in sensors. Tighten to 7 Nm, (60 in. lb). 27. Inspect the right and left air bag sensor wiring connectors. Is there is any sign of corrosion, (white, green or black), on either terminal of the harness connectors? a. Yes >>> Proceed to Step # 28. b. No >>> Proceed to Step # 39. NOTE: Only replace harness connectors that exhibit terminal corrosion. 28. Cut wire harness 3 in. (75 mm) back from connector. 29. Remove 1 in. (25 mm) of black tape from wire harness going to the vehicle. 30. Strip .5 in. (13 mm) of insulation from each wire. 31. Cut the new sensor connector wire harness p/n CBX2G092 the same length as the removed connector wire harness. 32. Strip .5 in. (13 mm) of insulation from each wire. 33. Slide one piece of heat shrink tubing on each of the wires. 34. Load and center the splice band into cavity "B" of crimp tool # 10042. Close the tool just enough to hold the splice band in place NOTE: First time use of crimp tool #10042 will require the crimp dies to be installed on the crimper frame. Orient the upper die with the arrow pointed up and the lower die with the arrow pointed forward. The numbers on upper die and letters on lower die will be on the same side. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1242 35. Match the new harness connector wires to the existing vehicle harness as follows: a. For the right (passenger side) sensor, match the new harness connector wire colors to the same color wire on the existing vehicle wire harness. b. For the left (driver side) sensor, match the new harness connector wire colors to the same tracer stripe color wire on the existing vehicle wire harness. CAUTION: Ensure wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 36. Insert the matched bare wires through the crimp connector from opposite ends. Crimp the connections using #10042 wire splice crimp tool. 37. Solder the crimped connection using only rosin-core solder. 38. Center heat shrink tubing over the connection and heat with a heat gun until tubing is tight and sealant is witnessed at the ends (Fig 7). CAUTION: Use only the sealant lined heat shrink tube supplied in wiring kit above. Use of electrical tape or non-sealant lined heat shrink tube may cause circuit failure. 39. Apply a small amount of dielectric grease, p/n J81 26688 to the airbag sensor connector end. Using a finger, force the grease into the terminal connections of the airbag sensor connector. 40. Connect the harness connectors to both front airbag sensors. 41. Has the fascia been removed? a. Yes >>> Proceed to Step # 42. b. No >>> Proceed to Step # 49. 42. Position the front fascia onto the vehicle. 43. Install the right and left upper fascia bolts, tighten to 5 Nm (50 in lb). 44. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender and tighten to 7 Nm (60 in lb). 45. Install the two vertical screws that secure the front fascia to the front fenders. 46. Install the two screws that secure the right and left wheelhouse shield to the front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1243 47. Using new push pins, if necessary, securing the air dam to the lower radiator crossmember. 48. Connect the electrical harness connectors to the right and left fog lamps, if equipped. 49. Connect the negative battery cable to the battery. 50. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel, and turn the ignition key to the "ON position. Wait 10 seconds: a. If the airbag warning light is not illuminated, the repair is complete. Proceed to to clear stored DTC's. b. If the airbag warning light is illuminated due to supplemental front airbag sensor faults, switch the ignition key "OFF and Proceed to and clear any DTC's. If the DTC's return and ARE related to the Front Impact Sensor(s), Verify proper wiring connections as described in above. If wiring connections are correct, or if DTC's are related to other components of the supplemental airbag system, refer to the diagnostic information available in DealerCONNECT >>> TechCONNECT under: Diagnostics > 7.2 AIRBAG for further information. 51. Turn the ignition "OFF" and connect the DRBIII(R). NOTE: The DRBIII(R) must be at software Version 64.0 or later. 52. Turn the ignition key to "ON". 53. Press the "YES" button when the DRBIII(R) powers up. 54. Select "DRBIII(R) STANDALONE" and press "ENTER". 55. Select "1997-2007 DIAGNOSTICS" and press "ENTER". 56. Select "ALL" and press "ENTER". 57. Select "PASSIVE RESTRAINT" and press "ENTER". 58. Select "CLEAR DTCS". 59. Disconnect and remove the DRBIII(R) from the vehicle. 60. Reset clock. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement Technical Service Bulletin # J38 Date: 100420 Campaign - Front Air Bag Sensor Replacement April 2010 Dealer Service Instructions for: Customer Satisfaction Notification J38 Supplemental Front Airbag Sensors Models 2005-2006 (RS) Dodge Caravan, Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles built from January 19, 2005 through April 5, 2006 (MDH 011900 through 040500). IMPORTANT: Many of the vehicles within the above build period have already been repaired according to our warranty records, and therefore, have been excluded from this notification. Only the above vehicles originally sold or currently registered in certain states are involved. See the "Owner Notification and Service Scheduling" section for a list of states involved in this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The supplemental front airbag sensors on about 310,000 of the above vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Repair The right and left supplemental front airbag sensors must be replaced and the sensor wiring harness connectors must be inspected and replaced, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1249 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1250 Parts Information Special Tools The following special tools may be required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1251 Use the labor operation numbers and time allowances as shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicableable. Only vehicles originally sold or currently registered in the following states are involved in this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1252 To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure A. Supplemental Front Airbag Sensor Replacement 1. Lower the driver's window completely. 2. Open the hood. 3. Disconnect and isolate the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Raise the vehicle on a suitable hoist. 5. Disconnect the wiring harness connector to the right and left supplemental front airbag sensor. The sensors are located on the outside of the right and left frame rails at the radiator lower crossmember (Figure 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1253 6. Remove the right and left supplemental front airbag sensors and discard the sensors and retaining bolts. CAUTION: If the retaining bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose from the radiator lower crossmember. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensor retaining bolts, continue with Step 9. 7. Use the following procedure, if required, to replace a spun riv-nut: a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps. b. Remove the four screws (two each side) that secure the left and right wheelhouse splash shield to the front fascia. c. Remove the right and left side fascia-to-fender bolts. d. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. e. Partially lower the vehicle. f. Remove the right and left fascia bolts from the upper radiator crossmember (Figure 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1254 g. Pull the wheelhouse shield back from the front fascia and remove the right and left nuts holding the front fascia to the front lip of the fender (Figure 3). h. Carefully remove the front fascia and set it aside. CAUTION: Be careful not to scratch the painted surfaces of the front fascia and front fenders. i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard. j. Using a cut-off wheel, remove the head of the airbag sensor mounting bolt. k. Remove and discard the supplemental front airbag sensor bushing. l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool. NOTE: Be sure to completely remove the riv-nut from the lower radiator crossmember. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1255 n. Pre-assemble the new riv-nut by installing the installation nut and the riv-nut onto the installation bolt as shown in Figure 4. o. Insert the new riv-nut-bolt/nut assembly into the original riv-nut hole in the lower radiator crossmember. p. Using a 10mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5). q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut. r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely). 8. For vehicles that had the front fascia removed, use the following procedure to install the front fascia: a. Position the front fascia onto the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1256 b. Install the right and left upper fascia bolts finger tight (Figure 6). c. Install the right and left nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m). d. Install and tighten the two fascia-to-fender bolts. e. Install the four screws (two on each side) that secure the right and left wheelhouse shield to the front fascia. f. Using new push pins if necessary, install the air dam to the lower radiator crossmember. g. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps. h. Continue with Step 9. 9. Inspect the right and left supplemental front airbag sensor wiring connectors. > If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B. Airbag Sensor Harness Connector Replacement. > If there is no corrosion on either terminal of the harness connectors, continue with Section C. Supplemental Front Airbag Sensor Installation. B. Airbag Sensor Harness Connector(s) Replacement NOTE: Only those harness connector(s) that exhibit terminal corrosion, as described in Section A, require replacement. 1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector. 2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness. 3. Remove 1/2 inch (13 mm) of insulation from each wire. 4. Cut the new harness connector wires so that the final length is equal to the old harness. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1257 5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire. 6. Slide one piece of heat shrink tubing onto each of the harness connector wires. 7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just enough to hold the splice band in place. 8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows: > For the right (passenger side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the purple (w/blue tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the white (w/blue tracer) wire on the body wiring harness. > For the left (driver's side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the blue (w/purple tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the blue (w/white tracer) wire on the body wiring harness. CAUTION: Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band. 10. Crimp the splice band and wires together by squeezing the crimping tool handles. NOTE: The tool will release once the proper crimping force has been achieved. 11. Solder the connection together using only rosin core type solder. CAUTION: DO NOT use acid core solder. 12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing. CAUTION: Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure. 13. Continue with Section C. Supplemental Front Airbag Sensor Installation. C. Supplemental Front Airbag Sensor Installation 1. Clean the supplemental front airbag sensor mounting surface for both sensors. 2. Install the new supplemental front airbag sensors using the fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091. NOTE: Use the bolts with a blue thread locker patch on the threads. Discard the pointed self tapping screws and flat washers. They will not be used in this repair procedure. 3. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. 4. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1258 5. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector (Figure 7). NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor wiring harness connector. 6. Connect the wiring harness connectors to the right and left supplemental front airbag sensors. 7. Lower the vehicle from the hoist. 8. For vehicles that had the Fascia removed, tighten the upper fascia bolts to 50 in. lbs. (5 N.m). 9. Connect the negative battery cable to the battery. 10. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "RUN" position. Wait 10 seconds: > If the airbag warning light is not illuminated, the repair has been completed. No further action is required, return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 11 to clear the Diagnostic Trouble Codes (DTC's). 11. Use the following procedure to clear DTC's: a. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. b. Turn the ignition key to the "RUN" position. c. Press the "YES" button after the DRBIII powers up. d. Select "DRBIII STANDALONE" and press "ENTER". e. Select "1998-2007 DIAGNOSTICS" and press "ENTER". f. Select "ALL" and press "ENTER". g. Select "PASSIVE RESTRAINT" and press "ENTER". h. Select "AIRBAG" and press "ENTER". i. Select "READ DTC's" and press "ENTER". j. Select "STORED" and press "ENTER". k. Press the "PAGE BACK" button and follow the screen prompts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1259 l. Disconnect and remove the DRBIII from the vehicle and return the vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set Technical Service Bulletin # 08-020-07 Date: 070713 Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set NUMBER: 08-020-07 GROUP: Electrical DATE: July 13, 2007 SUBJECT: Supplemental Front Air Bag Sensor Replacement (Lifetime Warranty) OVERVIEW: This bulletin involves verifying that a right and/or left front impact supplemental airbag sensor(s) Diagnostic Trouble Code (DTC) exists in the Occupant Restraint Control Module (ORG). If DTC's exist, the right and left supplemental front airbag sensors must be replaced and the sensor harness connectors must be inspected for corrosion and replaced if necessary. NOTE: Technicians performing this procedure for the first time should fully familiarize themselves with the steps and procedures listed in this Service Bulletin before proceeding. MODELS: 2005 (RG) Chrysler Voyager 2005 (RS) Town & Country/Caravan/Voyager NOTE: This bulletin applies to vehicles built at the Windsor Assembly Plant ("R" in the 11th VIN position) through February 3, 2005 (MDH 020323), the St. Louis Assembly plant ("B" in the 11th VIN position) through January 19, 2005 (MDH 011923) or the Styler Assembly plant ("Y" in the 11th VIN position) through January 04, 2005 (MDH 010423). DISCUSSION: The supplemental front airbag sensors may crack under certain conditions and allow water to enter into the sensor(s). These sensors were added to enhance the performance of the vehicles airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. DIAGNOSIS: If the vehicle operator experiences air bag warning lamp illumination with any of the following DTC's; NO RIGHT FRONT IMPACT SENSOR COMMUNICATION / RIGHT FRONT IMPACT SENSOR INTERNAL 1/ NO LEFT FRONT IMPACT SENSOR COMMUNICATION or LEFT FRONT IMPACT SENSOR INTERNAL 1, perform the Repair Procedure. If the air bag warning lamp is on due to other DTC's, this bulletin does not apply. Refer to diagnostic procedures available in DealerCONNECT >>> TechCONNECT under: Diagnostics > 7.2 AIRBAG for further information. NOTE: Vehicles that are included in Customer Satisfaction Notification G09 are not included in this Service Bulletin and must be repaired under the procedures and labor operation numbers listed within G09. Vehicles not included in G09 must use this Service Bulletin for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1264 PARTS REQUIRED: NOTE: Connectors, Self-Tapping Screws and Riv-nuts will be used on an "as needed" basis. SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. NOTE: Vehicles included in this Service Bulletin have a lifetime warranty on supplemental front airbag sensors, mounting hardware and sensor electrical connectors as described in this Service Bulletin. See Warranty Bulletin D-07-19 for details associated with the lifetime warranty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1265 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Lower the driver's side window. 2. Disconnect the Negative Battery Cable. 3. Refer to the detailed removal procedures available in DealerCONNECT >>> TechCONNECT under: Service Information Tab >>> Group 8, Electrical >>> Restraints >>> Impact Sensor >>> Removal. 4. When removing the attaching bolts for the sensor, does any of the bolts spin freely and not come out? (See NOTES below). a. Yes >>> Proceed to Step # 5 b. No >>> Proceed to Step # 22 NOTE: There are 2 types of bolts used to fasten the sensors to the radiator crossmember; a M7 self tapping bolt or a M6 bolt used with a riv-nut. If the bolt spins and cannot be removed, the riv-nut has broken loose. If the riv-nut spins and the bolt cannot be removed, proceed to next step to replace riv-nut(s). If no issue with the riv-nut is found, proceed to Step # 22. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1266 NOTE: The riv-nut procedure is applicable for vehicles built at the Windsor Assembly plant after May 24, 2004 or the St. Louis Assembly plant after June 28, 2004 or the Styler Assembly plant after June 28, 2004. Very few vehicles will require riv-nut replacement. 5. If the vehicle equipped with fog lamps, disconnect electrical harness connectors from both fog lamps. 6. Remove the 2 screws that secure the left and right wheelhouse splash shield to the front fascia. 7. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. 8. Remove the right and left fascia upper bolts from the upper radiator crossmember. (Fig 2) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1267 9. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Fig. 3) 10. Remove 2 vertical screws holding the front fascia to the front fender. 11. Carefully remove the front fascia and set aside. CAUTION: Care should be used not to damage painted surfaces. 12. Break the front air bag sensor using a suitable tool. Remove broken sensor pieces. 13. Using a powered cut-off wheel, remove the head of the sensor mounting bolt. 14. Remove sensor bushing from bolt. 15. Using a powered cut-off wheel, cut the bolt and lip of the riv-nut flush with sheet metal. 16. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. 17. Remove the old riv-nut through the access hole in the crossmember using a magnetic tool. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1268 18. Preassemble the new riv-nut, p/n CBX2G093 by installing the M6 nut, and the riv-nut onto the bolt, as shown in (Fig. 4). 19. Insert the riv-nut and bolt assembly into the original mounting hole. 20. Using a 10 mm crows foot, tighten the installation nut to 9 Nm, (80 in. lb) while holding the installation bolt stationary (Fig. 5). 21. Repeat Step # 12 through Step # 20 for remaining riv-nut(s) that have broken loose and spin freely. 22. Clean the mounting surface for both sensors. 23. Install the new sensors using the appropriate fasteners; Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1269 a. For sensors fastened with self-tapping bolts. Proceed to >>> # 24. b. For sensors fastened with M6 bolts and riv-nuts. Proceed to >>> Step # 26. 24. For self-tapping fastener installation; preassemble both air bag sensors with self-tapping bolts and washers (Fig. 6). 25. Position the sensors on the vehicle and tighten each self-tapping bolt into the mounting hole about 5 turns to cut new threads for the larger M7 bolt. Tighten to 7 Nm, (60 in. lb). Proceed to Step # 27. 26. For M6 bolt and riv-nut fastener installation; hand start both bolts in sensors. Tighten to 7 Nm, (60 in. lb). 27. Inspect the right and left air bag sensor wiring connectors. Is there is any sign of corrosion, (white, green or black), on either terminal of the harness connectors? a. Yes >>> Proceed to Step # 28. b. No >>> Proceed to Step # 39. NOTE: Only replace harness connectors that exhibit terminal corrosion. 28. Cut wire harness 3 in. (75 mm) back from connector. 29. Remove 1 in. (25 mm) of black tape from wire harness going to the vehicle. 30. Strip .5 in. (13 mm) of insulation from each wire. 31. Cut the new sensor connector wire harness p/n CBX2G092 the same length as the removed connector wire harness. 32. Strip .5 in. (13 mm) of insulation from each wire. 33. Slide one piece of heat shrink tubing on each of the wires. 34. Load and center the splice band into cavity "B" of crimp tool # 10042. Close the tool just enough to hold the splice band in place NOTE: First time use of crimp tool #10042 will require the crimp dies to be installed on the crimper frame. Orient the upper die with the arrow pointed up and the lower die with the arrow pointed forward. The numbers on upper die and letters on lower die will be on the same side. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1270 35. Match the new harness connector wires to the existing vehicle harness as follows: a. For the right (passenger side) sensor, match the new harness connector wire colors to the same color wire on the existing vehicle wire harness. b. For the left (driver side) sensor, match the new harness connector wire colors to the same tracer stripe color wire on the existing vehicle wire harness. CAUTION: Ensure wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 36. Insert the matched bare wires through the crimp connector from opposite ends. Crimp the connections using #10042 wire splice crimp tool. 37. Solder the crimped connection using only rosin-core solder. 38. Center heat shrink tubing over the connection and heat with a heat gun until tubing is tight and sealant is witnessed at the ends (Fig 7). CAUTION: Use only the sealant lined heat shrink tube supplied in wiring kit above. Use of electrical tape or non-sealant lined heat shrink tube may cause circuit failure. 39. Apply a small amount of dielectric grease, p/n J81 26688 to the airbag sensor connector end. Using a finger, force the grease into the terminal connections of the airbag sensor connector. 40. Connect the harness connectors to both front airbag sensors. 41. Has the fascia been removed? a. Yes >>> Proceed to Step # 42. b. No >>> Proceed to Step # 49. 42. Position the front fascia onto the vehicle. 43. Install the right and left upper fascia bolts, tighten to 5 Nm (50 in lb). 44. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender and tighten to 7 Nm (60 in lb). 45. Install the two vertical screws that secure the front fascia to the front fenders. 46. Install the two screws that secure the right and left wheelhouse shield to the front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1271 47. Using new push pins, if necessary, securing the air dam to the lower radiator crossmember. 48. Connect the electrical harness connectors to the right and left fog lamps, if equipped. 49. Connect the negative battery cable to the battery. 50. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel, and turn the ignition key to the "ON position. Wait 10 seconds: a. If the airbag warning light is not illuminated, the repair is complete. Proceed to to clear stored DTC's. b. If the airbag warning light is illuminated due to supplemental front airbag sensor faults, switch the ignition key "OFF and Proceed to and clear any DTC's. If the DTC's return and ARE related to the Front Impact Sensor(s), Verify proper wiring connections as described in above. If wiring connections are correct, or if DTC's are related to other components of the supplemental airbag system, refer to the diagnostic information available in DealerCONNECT >>> TechCONNECT under: Diagnostics > 7.2 AIRBAG for further information. 51. Turn the ignition "OFF" and connect the DRBIII(R). NOTE: The DRBIII(R) must be at software Version 64.0 or later. 52. Turn the ignition key to "ON". 53. Press the "YES" button when the DRBIII(R) powers up. 54. Select "DRBIII(R) STANDALONE" and press "ENTER". 55. Select "1997-2007 DIAGNOSTICS" and press "ENTER". 56. Select "ALL" and press "ENTER". 57. Select "PASSIVE RESTRAINT" and press "ENTER". 58. Select "CLEAR DTCS". 59. Disconnect and remove the DRBIII(R) from the vehicle. 60. Reset clock. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement Technical Service Bulletin # G09 Date: 070601 Recall - Front Air Bag Impact Sensor Replacement June 2007 Dealer Service Instructions for: Customer Satisfaction Notification G09 Supplemental Front Airbag Sensors Models 2005 (RS) Dodge Caravan, Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles built at the Windsor Assembly plant ("R" in the 11th VIN position) through February 3, 2005 (MDH 020323) and the St. Louis Assembly plant ("B" in the 11th VIN position) through January 19, 2005 (MDH 011923). IMPORTANT: Many of the vehicles within the above build period have already been repaired according to our warranty records, and therefore, have been excluded from this notification. Only the above vehicles originally sold or currently registered in certain states are involved. See the "Owner Notification and Service Scheduling" section for a list of states involved in this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair service on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The supplemental front airbag sensors on about 263,000 of the above vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Repair The right and left supplemental front airbag sensors must be replaced and the sensor harness connectors must be inspected and replaced, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1276 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1277 Parts Information Special Tools The special tools may be required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record repair service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1278 Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Attached to each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Only vehicles originally sold or currently registered in the following states are involved in this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Supplemental Front Airbag Sensor Replacement 1. Lower the driver¡C■s window completely. 2. Open the hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1279 3. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Raise the vehicle on a suitable hoist. 5. Disconnect the harness connector to the right and left supplemental front airbag sensor (Figure 1). 6. Remove the right and left supplemental front airbag sensors and discard the bolts and sensors. NOTE: There are two types of bolts used to fasten the sensors to the radiator crossmember; an M7 self tapping bolt or an M6 bolt used with a riv-nut. If the bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensors, continue with Step 8. 7. Replaced a spun riv-nut as follows: NOTE: The following procedure is applicable for vehicle built at the Windsor Assembly Plant after May 24, 2004 or the St. Louis Assembly Plant after June 28, 2004. Very few vehicles are expected to require riv-nut replacement. a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps. b. Remove the two screws that secure the left and right wheelhouse splash shield to the front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1280 c Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. d. Partially lower the vehicle. e. Remove the right and left fascia upper bolts from the upper radiator crossmember (Figure 2). f. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Figure 3) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1281 g. Remove the two vertical screws holding the front fascia to the front fender. h. Carefully remove the front fascia and set it aside. CAUTION: Be careful not to scratch the painted surfaces of the front fascia and the front fenders. i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard. j. Using a cut-off wheel, cut off the head of the airbag sensor mounting bolt. k. Remove and discard the supplemental front airbag sensor bushing. l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool. NOTE: Be sure to completely remove the riv-nut from the lower radiator crossmember. n. Pre-assemble the new riv-nut by installing the M6 nut and the riv-nut onto the M6 bolt as shown in Figure 4. o. Insert the riv-nut-bolt/nut assembly into the body sheet metal hole. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1282 p. Using a 10 mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5). q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut. r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely). s. Clean the supplemental front airbag sensor mounting surface for both sensors. t. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091: > For sensors fastened with self tapping bolts: a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6. b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts. c. Tightening the self tapping bolts to 60 in.lbs. (7 N.m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1283 > For sensors fastened with M6 bolts and riv-nuts: a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). u. Inspect the right and left supplemental front airbag sensor wiring connectors. If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B Harness Connector Replacement. v. Position the front fascia onto the vehicle. w. Install the right and left upper bolts fascia bolts and tighten to 50 in. lbs. (5 N.m). x. Install the right and left horizontal nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m). y. Install and tighten the two vertical screws that secure the front fascia to the front fenders. z. Install the two screws that secure the right and left wheelhouse shield to the front fascia. aa. Using new push pins if necessary, install the air dam to the lower radiator crossmember. ab. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps. ac. Continue with Step 10. 8. Clean the supplemental front airbag sensor mounting surface for both sensors. 9. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091: > For sensors fastened with self tapping bolts: a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6. b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts. c. Tightening the self tapping bolts to 60 in. lbs. (7 N.m). > For sensors fastened with M6 bolts and riv-nuts: a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). 10. Inspect the right and left supplemental front airbag sensor wiring connectors. If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B - Harness Connector Replacement. 11. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector. NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector. 12. Connect harness connectors to the right and left supplemental front airbag sensors. 13. Lower the vehicle. 14. Connect the negative battery cable to the battery. 15. Stand next to the vehicle with the driver¡C■s door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "ON" position. Wait 10 seconds: > If the airbag warning light is not illuminated the repair has been completed. Return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1284 continue with Step 16 to clear the sensor DTC. 16. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. 17. Turn the ignition key to the "ON" position. 18. Press the "YES" button when the DRBIII powers up. 19. Select "DRBIII STANDALONE" and press "ENTER". 20. Select "1997-2007 DIAGNOSTICS" and press "ENTER". 21. Select "ALL" and press "ENTER" 22. Select "PASSIVE RESTRAINT" and press "ENTER". 23. Select "CLEAR DTCS". 24. Disconnect and remove the DRBIII from the vehicle. B. Airbag Sensor Harness Connector Replacement NOTE: Only those harness connectors that exhibit terminal corrosion, as described in Section A, require replacement. 1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector. 2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness. 3. Remove 1/2 inch (13 mm) of insulation from each wire. 4. Cut the new harness connector wires so that the final length is equal to the old harness. 5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire. 6. Slide one piece of heat shrink tubing onto each of the harness connector wires. 7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just the tool just CAUTION: The crimp jaw must be installed in the crimp tool frame as shown in Figure 7. The crimp jaw wire gauge numbers must be on the same side. When installing the crimp jaw into the tool frame, orient the upper die with the arrow pointed "up" and the lower die with the arrow pointed forward. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1285 8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows: > For the right (passenger side) supplemental front airbag sensor, match the new harness connector wire colors to the same color wire on the existing body wire harness. > For the left (driver's side) supplemental front airbag sensor, match the new harness connector wire colors to same tracer (stripe) color wire on the existing body wire harness. CAUTION: Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. warning lamp. 9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band (Figure 8). 10. Crimp the splice band and wires together by squeezing the crimping tool handles. The tool will release once the proper crimping force has been achieved (Figure 8). 11. Solder the connection together using only rosin-core type solder (Figure. 9). CAUTION: DO NOT use acid core solder. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1286 12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Figure 10). CAUTION: Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure. 13. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector. NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector. 14. Connect harness connectors to the right and left supplemental front airbag sensors. 15. For vehicles with the front fascia removed: a. Position the front fascia onto the vehicle. b. Install the right and left upper fascia bolts and tighten to 50 in. lbs. (5 N.m). c. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender. Tighten the nuts to 60 in. lbs. (7 N.m). d. Install and tighten the two vertical screws that secure the front fascia to the front fenders. e. Install the two screws that secure the right and left wheelhouse shield to the front fascia. f. Using new push pins if necessary, securing the air dam to the lower radiator crossmember. g. For vehicles with fog lamps, connect the electrical harness connectors to the right and left fog lamps. 16. Lower the vehicle. 17. Connect the negative battery cable to the battery. 18. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel, and turn the ignition key to the "ON" position. Wait 10 seconds: > If the airbag warning light is not illuminated, the repair has been completed. Return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 19 to clear the sensor DTC. 19. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. 20. Turn the ignition key to the "ON" position. 21. Press the "YES" button when the DRBIII powers up. 22. Select "DRBIII STANDALONE" and press "ENTER". 23. Select "1997-2007 DIAGNOSTICS" and press "ENTER". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1287 24. Select "ALL" and press "ENTER". 25. Select "PASSIVE RESTRAINT" and press "ENTER". 26. Select "CLEAR DTCS". 27. Disconnect and remove the DRBIII from the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > NHTSA07V192000 > May > 07 > Recall 07V191000: Air Bag Impact Sensor Replacement Impact Sensor: All Technical Service Bulletins Recall 07V191000: Air Bag Impact Sensor Replacement MAKE/MODELS: MODEL/BUILD YEARS: Chrysler/Town & Country 2005 Dodge/Caravan 2005 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V192000 MFR'S REPORT DATE: May 01, 2007 COMPONENT: Air Bags: Frontal: Sensor/Control Module POTENTIAL NUMBER OF UNITS AFFECTED: 270958 SUMMARY: Certain minivans are being recalled that were originally sold in or currently registered in the 27 states plus The District of Columbia that use greater amounts of salt for Winter road deicing. The Up-Front (UF) air bag sensors that contain brass bushings installed in these vehicles may corrode and crack allowing water to enter the sensor. These sensors provide enhanced air bag performance in certain types of frontal crashes. CONSEQUENCE: In one of these crashes, with one or both of the vehicle the vehicle's UF sensors inoperative, the occupants will not benefit from the enhanced air bag protection that these sensors would provide. REMEDY: For vehicles registered in the recall states, dealers will replace the original UF air bag sensors with ones with greater corrosion resistance. Vehicles registered in other states will obtain a lifetime free replacement of any UF sensor that fails. The campaign is expected to begin during July 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler's campaign Nos. G09/X16. DaimlerChrysler has not decided that this is a defect related to motor vehicle safety. However, it has informed NHTSA that it will provide the modifications described above free of charge. Customers also may contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline aT 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set Technical Service Bulletin # 08-020-07 Date: 070713 Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set NUMBER: 08-020-07 GROUP: Electrical DATE: July 13, 2007 SUBJECT: Supplemental Front Air Bag Sensor Replacement (Lifetime Warranty) OVERVIEW: This bulletin involves verifying that a right and/or left front impact supplemental airbag sensor(s) Diagnostic Trouble Code (DTC) exists in the Occupant Restraint Control Module (ORG). If DTC's exist, the right and left supplemental front airbag sensors must be replaced and the sensor harness connectors must be inspected for corrosion and replaced if necessary. NOTE: Technicians performing this procedure for the first time should fully familiarize themselves with the steps and procedures listed in this Service Bulletin before proceeding. MODELS: 2005 (RG) Chrysler Voyager 2005 (RS) Town & Country/Caravan/Voyager NOTE: This bulletin applies to vehicles built at the Windsor Assembly Plant ("R" in the 11th VIN position) through February 3, 2005 (MDH 020323), the St. Louis Assembly plant ("B" in the 11th VIN position) through January 19, 2005 (MDH 011923) or the Styler Assembly plant ("Y" in the 11th VIN position) through January 04, 2005 (MDH 010423). DISCUSSION: The supplemental front airbag sensors may crack under certain conditions and allow water to enter into the sensor(s). These sensors were added to enhance the performance of the vehicles airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. DIAGNOSIS: If the vehicle operator experiences air bag warning lamp illumination with any of the following DTC's; NO RIGHT FRONT IMPACT SENSOR COMMUNICATION / RIGHT FRONT IMPACT SENSOR INTERNAL 1/ NO LEFT FRONT IMPACT SENSOR COMMUNICATION or LEFT FRONT IMPACT SENSOR INTERNAL 1, perform the Repair Procedure. If the air bag warning lamp is on due to other DTC's, this bulletin does not apply. Refer to diagnostic procedures available in DealerCONNECT >>> TechCONNECT under: Diagnostics > 7.2 AIRBAG for further information. NOTE: Vehicles that are included in Customer Satisfaction Notification G09 are not included in this Service Bulletin and must be repaired under the procedures and labor operation numbers listed within G09. Vehicles not included in G09 must use this Service Bulletin for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1297 PARTS REQUIRED: NOTE: Connectors, Self-Tapping Screws and Riv-nuts will be used on an "as needed" basis. SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. NOTE: Vehicles included in this Service Bulletin have a lifetime warranty on supplemental front airbag sensors, mounting hardware and sensor electrical connectors as described in this Service Bulletin. See Warranty Bulletin D-07-19 for details associated with the lifetime warranty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1298 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Lower the driver's side window. 2. Disconnect the Negative Battery Cable. 3. Refer to the detailed removal procedures available in DealerCONNECT >>> TechCONNECT under: Service Information Tab >>> Group 8, Electrical >>> Restraints >>> Impact Sensor >>> Removal. 4. When removing the attaching bolts for the sensor, does any of the bolts spin freely and not come out? (See NOTES below). a. Yes >>> Proceed to Step # 5 b. No >>> Proceed to Step # 22 NOTE: There are 2 types of bolts used to fasten the sensors to the radiator crossmember; a M7 self tapping bolt or a M6 bolt used with a riv-nut. If the bolt spins and cannot be removed, the riv-nut has broken loose. If the riv-nut spins and the bolt cannot be removed, proceed to next step to replace riv-nut(s). If no issue with the riv-nut is found, proceed to Step # 22. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1299 NOTE: The riv-nut procedure is applicable for vehicles built at the Windsor Assembly plant after May 24, 2004 or the St. Louis Assembly plant after June 28, 2004 or the Styler Assembly plant after June 28, 2004. Very few vehicles will require riv-nut replacement. 5. If the vehicle equipped with fog lamps, disconnect electrical harness connectors from both fog lamps. 6. Remove the 2 screws that secure the left and right wheelhouse splash shield to the front fascia. 7. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. 8. Remove the right and left fascia upper bolts from the upper radiator crossmember. (Fig 2) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1300 9. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Fig. 3) 10. Remove 2 vertical screws holding the front fascia to the front fender. 11. Carefully remove the front fascia and set aside. CAUTION: Care should be used not to damage painted surfaces. 12. Break the front air bag sensor using a suitable tool. Remove broken sensor pieces. 13. Using a powered cut-off wheel, remove the head of the sensor mounting bolt. 14. Remove sensor bushing from bolt. 15. Using a powered cut-off wheel, cut the bolt and lip of the riv-nut flush with sheet metal. 16. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. 17. Remove the old riv-nut through the access hole in the crossmember using a magnetic tool. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1301 18. Preassemble the new riv-nut, p/n CBX2G093 by installing the M6 nut, and the riv-nut onto the bolt, as shown in (Fig. 4). 19. Insert the riv-nut and bolt assembly into the original mounting hole. 20. Using a 10 mm crows foot, tighten the installation nut to 9 Nm, (80 in. lb) while holding the installation bolt stationary (Fig. 5). 21. Repeat Step # 12 through Step # 20 for remaining riv-nut(s) that have broken loose and spin freely. 22. Clean the mounting surface for both sensors. 23. Install the new sensors using the appropriate fasteners; Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1302 a. For sensors fastened with self-tapping bolts. Proceed to >>> # 24. b. For sensors fastened with M6 bolts and riv-nuts. Proceed to >>> Step # 26. 24. For self-tapping fastener installation; preassemble both air bag sensors with self-tapping bolts and washers (Fig. 6). 25. Position the sensors on the vehicle and tighten each self-tapping bolt into the mounting hole about 5 turns to cut new threads for the larger M7 bolt. Tighten to 7 Nm, (60 in. lb). Proceed to Step # 27. 26. For M6 bolt and riv-nut fastener installation; hand start both bolts in sensors. Tighten to 7 Nm, (60 in. lb). 27. Inspect the right and left air bag sensor wiring connectors. Is there is any sign of corrosion, (white, green or black), on either terminal of the harness connectors? a. Yes >>> Proceed to Step # 28. b. No >>> Proceed to Step # 39. NOTE: Only replace harness connectors that exhibit terminal corrosion. 28. Cut wire harness 3 in. (75 mm) back from connector. 29. Remove 1 in. (25 mm) of black tape from wire harness going to the vehicle. 30. Strip .5 in. (13 mm) of insulation from each wire. 31. Cut the new sensor connector wire harness p/n CBX2G092 the same length as the removed connector wire harness. 32. Strip .5 in. (13 mm) of insulation from each wire. 33. Slide one piece of heat shrink tubing on each of the wires. 34. Load and center the splice band into cavity "B" of crimp tool # 10042. Close the tool just enough to hold the splice band in place NOTE: First time use of crimp tool #10042 will require the crimp dies to be installed on the crimper frame. Orient the upper die with the arrow pointed up and the lower die with the arrow pointed forward. The numbers on upper die and letters on lower die will be on the same side. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1303 35. Match the new harness connector wires to the existing vehicle harness as follows: a. For the right (passenger side) sensor, match the new harness connector wire colors to the same color wire on the existing vehicle wire harness. b. For the left (driver side) sensor, match the new harness connector wire colors to the same tracer stripe color wire on the existing vehicle wire harness. CAUTION: Ensure wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 36. Insert the matched bare wires through the crimp connector from opposite ends. Crimp the connections using #10042 wire splice crimp tool. 37. Solder the crimped connection using only rosin-core solder. 38. Center heat shrink tubing over the connection and heat with a heat gun until tubing is tight and sealant is witnessed at the ends (Fig 7). CAUTION: Use only the sealant lined heat shrink tube supplied in wiring kit above. Use of electrical tape or non-sealant lined heat shrink tube may cause circuit failure. 39. Apply a small amount of dielectric grease, p/n J81 26688 to the airbag sensor connector end. Using a finger, force the grease into the terminal connections of the airbag sensor connector. 40. Connect the harness connectors to both front airbag sensors. 41. Has the fascia been removed? a. Yes >>> Proceed to Step # 42. b. No >>> Proceed to Step # 49. 42. Position the front fascia onto the vehicle. 43. Install the right and left upper fascia bolts, tighten to 5 Nm (50 in lb). 44. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender and tighten to 7 Nm (60 in lb). 45. Install the two vertical screws that secure the front fascia to the front fenders. 46. Install the two screws that secure the right and left wheelhouse shield to the front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 1304 47. Using new push pins, if necessary, securing the air dam to the lower radiator crossmember. 48. Connect the electrical harness connectors to the right and left fog lamps, if equipped. 49. Connect the negative battery cable to the battery. 50. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel, and turn the ignition key to the "ON position. Wait 10 seconds: a. If the airbag warning light is not illuminated, the repair is complete. Proceed to to clear stored DTC's. b. If the airbag warning light is illuminated due to supplemental front airbag sensor faults, switch the ignition key "OFF and Proceed to and clear any DTC's. If the DTC's return and ARE related to the Front Impact Sensor(s), Verify proper wiring connections as described in above. If wiring connections are correct, or if DTC's are related to other components of the supplemental airbag system, refer to the diagnostic information available in DealerCONNECT >>> TechCONNECT under: Diagnostics > 7.2 AIRBAG for further information. 51. Turn the ignition "OFF" and connect the DRBIII(R). NOTE: The DRBIII(R) must be at software Version 64.0 or later. 52. Turn the ignition key to "ON". 53. Press the "YES" button when the DRBIII(R) powers up. 54. Select "DRBIII(R) STANDALONE" and press "ENTER". 55. Select "1997-2007 DIAGNOSTICS" and press "ENTER". 56. Select "ALL" and press "ENTER". 57. Select "PASSIVE RESTRAINT" and press "ENTER". 58. Select "CLEAR DTCS". 59. Disconnect and remove the DRBIII(R) from the vehicle. 60. Reset clock. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement Technical Service Bulletin # J38 Date: 100420 Campaign - Front Air Bag Sensor Replacement April 2010 Dealer Service Instructions for: Customer Satisfaction Notification J38 Supplemental Front Airbag Sensors Models 2005-2006 (RS) Dodge Caravan, Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles built from January 19, 2005 through April 5, 2006 (MDH 011900 through 040500). IMPORTANT: Many of the vehicles within the above build period have already been repaired according to our warranty records, and therefore, have been excluded from this notification. Only the above vehicles originally sold or currently registered in certain states are involved. See the "Owner Notification and Service Scheduling" section for a list of states involved in this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The supplemental front airbag sensors on about 310,000 of the above vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Repair The right and left supplemental front airbag sensors must be replaced and the sensor wiring harness connectors must be inspected and replaced, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1310 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1311 Parts Information Special Tools The following special tools may be required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1312 Use the labor operation numbers and time allowances as shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicableable. Only vehicles originally sold or currently registered in the following states are involved in this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1313 To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure A. Supplemental Front Airbag Sensor Replacement 1. Lower the driver's window completely. 2. Open the hood. 3. Disconnect and isolate the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Raise the vehicle on a suitable hoist. 5. Disconnect the wiring harness connector to the right and left supplemental front airbag sensor. The sensors are located on the outside of the right and left frame rails at the radiator lower crossmember (Figure 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1314 6. Remove the right and left supplemental front airbag sensors and discard the sensors and retaining bolts. CAUTION: If the retaining bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose from the radiator lower crossmember. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensor retaining bolts, continue with Step 9. 7. Use the following procedure, if required, to replace a spun riv-nut: a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps. b. Remove the four screws (two each side) that secure the left and right wheelhouse splash shield to the front fascia. c. Remove the right and left side fascia-to-fender bolts. d. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. e. Partially lower the vehicle. f. Remove the right and left fascia bolts from the upper radiator crossmember (Figure 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1315 g. Pull the wheelhouse shield back from the front fascia and remove the right and left nuts holding the front fascia to the front lip of the fender (Figure 3). h. Carefully remove the front fascia and set it aside. CAUTION: Be careful not to scratch the painted surfaces of the front fascia and front fenders. i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard. j. Using a cut-off wheel, remove the head of the airbag sensor mounting bolt. k. Remove and discard the supplemental front airbag sensor bushing. l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool. NOTE: Be sure to completely remove the riv-nut from the lower radiator crossmember. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1316 n. Pre-assemble the new riv-nut by installing the installation nut and the riv-nut onto the installation bolt as shown in Figure 4. o. Insert the new riv-nut-bolt/nut assembly into the original riv-nut hole in the lower radiator crossmember. p. Using a 10mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5). q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut. r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely). 8. For vehicles that had the front fascia removed, use the following procedure to install the front fascia: a. Position the front fascia onto the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1317 b. Install the right and left upper fascia bolts finger tight (Figure 6). c. Install the right and left nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m). d. Install and tighten the two fascia-to-fender bolts. e. Install the four screws (two on each side) that secure the right and left wheelhouse shield to the front fascia. f. Using new push pins if necessary, install the air dam to the lower radiator crossmember. g. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps. h. Continue with Step 9. 9. Inspect the right and left supplemental front airbag sensor wiring connectors. > If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B. Airbag Sensor Harness Connector Replacement. > If there is no corrosion on either terminal of the harness connectors, continue with Section C. Supplemental Front Airbag Sensor Installation. B. Airbag Sensor Harness Connector(s) Replacement NOTE: Only those harness connector(s) that exhibit terminal corrosion, as described in Section A, require replacement. 1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector. 2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness. 3. Remove 1/2 inch (13 mm) of insulation from each wire. 4. Cut the new harness connector wires so that the final length is equal to the old harness. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1318 5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire. 6. Slide one piece of heat shrink tubing onto each of the harness connector wires. 7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just enough to hold the splice band in place. 8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows: > For the right (passenger side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the purple (w/blue tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the white (w/blue tracer) wire on the body wiring harness. > For the left (driver's side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the blue (w/purple tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the blue (w/white tracer) wire on the body wiring harness. CAUTION: Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band. 10. Crimp the splice band and wires together by squeezing the crimping tool handles. NOTE: The tool will release once the proper crimping force has been achieved. 11. Solder the connection together using only rosin core type solder. CAUTION: DO NOT use acid core solder. 12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing. CAUTION: Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure. 13. Continue with Section C. Supplemental Front Airbag Sensor Installation. C. Supplemental Front Airbag Sensor Installation 1. Clean the supplemental front airbag sensor mounting surface for both sensors. 2. Install the new supplemental front airbag sensors using the fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091. NOTE: Use the bolts with a blue thread locker patch on the threads. Discard the pointed self tapping screws and flat washers. They will not be used in this repair procedure. 3. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. 4. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1319 5. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector (Figure 7). NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor wiring harness connector. 6. Connect the wiring harness connectors to the right and left supplemental front airbag sensors. 7. Lower the vehicle from the hoist. 8. For vehicles that had the Fascia removed, tighten the upper fascia bolts to 50 in. lbs. (5 N.m). 9. Connect the negative battery cable to the battery. 10. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "RUN" position. Wait 10 seconds: > If the airbag warning light is not illuminated, the repair has been completed. No further action is required, return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 11 to clear the Diagnostic Trouble Codes (DTC's). 11. Use the following procedure to clear DTC's: a. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. b. Turn the ignition key to the "RUN" position. c. Press the "YES" button after the DRBIII powers up. d. Select "DRBIII STANDALONE" and press "ENTER". e. Select "1998-2007 DIAGNOSTICS" and press "ENTER". f. Select "ALL" and press "ENTER". g. Select "PASSIVE RESTRAINT" and press "ENTER". h. Select "AIRBAG" and press "ENTER". i. Select "READ DTC's" and press "ENTER". j. Select "STORED" and press "ENTER". k. Press the "PAGE BACK" button and follow the screen prompts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 1320 l. Disconnect and remove the DRBIII from the vehicle and return the vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement Technical Service Bulletin # G09 Date: 070601 Recall - Front Air Bag Impact Sensor Replacement June 2007 Dealer Service Instructions for: Customer Satisfaction Notification G09 Supplemental Front Airbag Sensors Models 2005 (RS) Dodge Caravan, Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles built at the Windsor Assembly plant ("R" in the 11th VIN position) through February 3, 2005 (MDH 020323) and the St. Louis Assembly plant ("B" in the 11th VIN position) through January 19, 2005 (MDH 011923). IMPORTANT: Many of the vehicles within the above build period have already been repaired according to our warranty records, and therefore, have been excluded from this notification. Only the above vehicles originally sold or currently registered in certain states are involved. See the "Owner Notification and Service Scheduling" section for a list of states involved in this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair service on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The supplemental front airbag sensors on about 263,000 of the above vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Repair The right and left supplemental front airbag sensors must be replaced and the sensor harness connectors must be inspected and replaced, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1325 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1326 Parts Information Special Tools The special tools may be required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record repair service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1327 Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Attached to each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Only vehicles originally sold or currently registered in the following states are involved in this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Supplemental Front Airbag Sensor Replacement 1. Lower the driver¡C■s window completely. 2. Open the hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1328 3. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Raise the vehicle on a suitable hoist. 5. Disconnect the harness connector to the right and left supplemental front airbag sensor (Figure 1). 6. Remove the right and left supplemental front airbag sensors and discard the bolts and sensors. NOTE: There are two types of bolts used to fasten the sensors to the radiator crossmember; an M7 self tapping bolt or an M6 bolt used with a riv-nut. If the bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensors, continue with Step 8. 7. Replaced a spun riv-nut as follows: NOTE: The following procedure is applicable for vehicle built at the Windsor Assembly Plant after May 24, 2004 or the St. Louis Assembly Plant after June 28, 2004. Very few vehicles are expected to require riv-nut replacement. a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps. b. Remove the two screws that secure the left and right wheelhouse splash shield to the front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1329 c Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. d. Partially lower the vehicle. e. Remove the right and left fascia upper bolts from the upper radiator crossmember (Figure 2). f. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Figure 3) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1330 g. Remove the two vertical screws holding the front fascia to the front fender. h. Carefully remove the front fascia and set it aside. CAUTION: Be careful not to scratch the painted surfaces of the front fascia and the front fenders. i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard. j. Using a cut-off wheel, cut off the head of the airbag sensor mounting bolt. k. Remove and discard the supplemental front airbag sensor bushing. l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool. NOTE: Be sure to completely remove the riv-nut from the lower radiator crossmember. n. Pre-assemble the new riv-nut by installing the M6 nut and the riv-nut onto the M6 bolt as shown in Figure 4. o. Insert the riv-nut-bolt/nut assembly into the body sheet metal hole. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1331 p. Using a 10 mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5). q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut. r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely). s. Clean the supplemental front airbag sensor mounting surface for both sensors. t. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091: > For sensors fastened with self tapping bolts: a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6. b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts. c. Tightening the self tapping bolts to 60 in.lbs. (7 N.m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1332 > For sensors fastened with M6 bolts and riv-nuts: a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). u. Inspect the right and left supplemental front airbag sensor wiring connectors. If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B Harness Connector Replacement. v. Position the front fascia onto the vehicle. w. Install the right and left upper bolts fascia bolts and tighten to 50 in. lbs. (5 N.m). x. Install the right and left horizontal nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m). y. Install and tighten the two vertical screws that secure the front fascia to the front fenders. z. Install the two screws that secure the right and left wheelhouse shield to the front fascia. aa. Using new push pins if necessary, install the air dam to the lower radiator crossmember. ab. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps. ac. Continue with Step 10. 8. Clean the supplemental front airbag sensor mounting surface for both sensors. 9. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091: > For sensors fastened with self tapping bolts: a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6. b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts. c. Tightening the self tapping bolts to 60 in. lbs. (7 N.m). > For sensors fastened with M6 bolts and riv-nuts: a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). 10. Inspect the right and left supplemental front airbag sensor wiring connectors. If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B - Harness Connector Replacement. 11. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector. NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector. 12. Connect harness connectors to the right and left supplemental front airbag sensors. 13. Lower the vehicle. 14. Connect the negative battery cable to the battery. 15. Stand next to the vehicle with the driver¡C■s door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "ON" position. Wait 10 seconds: > If the airbag warning light is not illuminated the repair has been completed. Return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1333 continue with Step 16 to clear the sensor DTC. 16. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. 17. Turn the ignition key to the "ON" position. 18. Press the "YES" button when the DRBIII powers up. 19. Select "DRBIII STANDALONE" and press "ENTER". 20. Select "1997-2007 DIAGNOSTICS" and press "ENTER". 21. Select "ALL" and press "ENTER" 22. Select "PASSIVE RESTRAINT" and press "ENTER". 23. Select "CLEAR DTCS". 24. Disconnect and remove the DRBIII from the vehicle. B. Airbag Sensor Harness Connector Replacement NOTE: Only those harness connectors that exhibit terminal corrosion, as described in Section A, require replacement. 1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector. 2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness. 3. Remove 1/2 inch (13 mm) of insulation from each wire. 4. Cut the new harness connector wires so that the final length is equal to the old harness. 5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire. 6. Slide one piece of heat shrink tubing onto each of the harness connector wires. 7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just the tool just CAUTION: The crimp jaw must be installed in the crimp tool frame as shown in Figure 7. The crimp jaw wire gauge numbers must be on the same side. When installing the crimp jaw into the tool frame, orient the upper die with the arrow pointed "up" and the lower die with the arrow pointed forward. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1334 8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows: > For the right (passenger side) supplemental front airbag sensor, match the new harness connector wire colors to the same color wire on the existing body wire harness. > For the left (driver's side) supplemental front airbag sensor, match the new harness connector wire colors to same tracer (stripe) color wire on the existing body wire harness. CAUTION: Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. warning lamp. 9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band (Figure 8). 10. Crimp the splice band and wires together by squeezing the crimping tool handles. The tool will release once the proper crimping force has been achieved (Figure 8). 11. Solder the connection together using only rosin-core type solder (Figure. 9). CAUTION: DO NOT use acid core solder. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1335 12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Figure 10). CAUTION: Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure. 13. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector. NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector. 14. Connect harness connectors to the right and left supplemental front airbag sensors. 15. For vehicles with the front fascia removed: a. Position the front fascia onto the vehicle. b. Install the right and left upper fascia bolts and tighten to 50 in. lbs. (5 N.m). c. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender. Tighten the nuts to 60 in. lbs. (7 N.m). d. Install and tighten the two vertical screws that secure the front fascia to the front fenders. e. Install the two screws that secure the right and left wheelhouse shield to the front fascia. f. Using new push pins if necessary, securing the air dam to the lower radiator crossmember. g. For vehicles with fog lamps, connect the electrical harness connectors to the right and left fog lamps. 16. Lower the vehicle. 17. Connect the negative battery cable to the battery. 18. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel, and turn the ignition key to the "ON" position. Wait 10 seconds: > If the airbag warning light is not illuminated, the repair has been completed. Return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 19 to clear the sensor DTC. 19. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. 20. Turn the ignition key to the "ON" position. 21. Press the "YES" button when the DRBIII powers up. 22. Select "DRBIII STANDALONE" and press "ENTER". 23. Select "1997-2007 DIAGNOSTICS" and press "ENTER". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 1336 24. Select "ALL" and press "ENTER". 25. Select "PASSIVE RESTRAINT" and press "ENTER". 26. Select "CLEAR DTCS". 27. Disconnect and remove the DRBIII from the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > NHTSA07V192000 > May > 07 > Recall 07V191000: Air Bag Impact Sensor Replacement Impact Sensor: All Technical Service Bulletins Recall 07V191000: Air Bag Impact Sensor Replacement MAKE/MODELS: MODEL/BUILD YEARS: Chrysler/Town & Country 2005 Dodge/Caravan 2005 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V192000 MFR'S REPORT DATE: May 01, 2007 COMPONENT: Air Bags: Frontal: Sensor/Control Module POTENTIAL NUMBER OF UNITS AFFECTED: 270958 SUMMARY: Certain minivans are being recalled that were originally sold in or currently registered in the 27 states plus The District of Columbia that use greater amounts of salt for Winter road deicing. The Up-Front (UF) air bag sensors that contain brass bushings installed in these vehicles may corrode and crack allowing water to enter the sensor. These sensors provide enhanced air bag performance in certain types of frontal crashes. CONSEQUENCE: In one of these crashes, with one or both of the vehicle the vehicle's UF sensors inoperative, the occupants will not benefit from the enhanced air bag protection that these sensors would provide. REMEDY: For vehicles registered in the recall states, dealers will replace the original UF air bag sensors with ones with greater corrosion resistance. Vehicles registered in other states will obtain a lifetime free replacement of any UF sensor that fails. The campaign is expected to begin during July 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler's campaign Nos. G09/X16. DaimlerChrysler has not decided that this is a defect related to motor vehicle safety. However, it has informed NHTSA that it will provide the modifications described above free of charge. Customers also may contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline aT 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Component Locations Impact Sensor: Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Component Locations > Page 1343 Impact Sensor: Connector Locations Left Fender Shield Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Component Locations > Page 1344 Right Side Body RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Component Locations > Page 1345 Right B Pillar Left B Pillar Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Component Locations > Page 1346 Left Rear Body Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Component Locations > Page 1347 Right Quarter Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1348 Impact Sensor: Diagrams Left Front Impact Sensor (Except Export Early Build) Left Front Impact Sensor (Export Early Build) Left Side Impact Sensor 1 (Except Export Early Build) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1349 Left Side Impact Sensor 1 (Export Early Build) Left Side Impact Sensor 2 Left Side Impact Sensor 3 (Except Export Late Build) Left Side Impact Sensor 3 (Export Late Build) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1350 Right Front Impact Sensor Right Side Impact Sensor 1 (Except Export Early Build) Right Side Impact Sensor 1 (Export Early Build) Right Side Impact Sensor 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1351 Right Side Impact Sensor 3 (Except Export Late Build) Right Side Impact Sensor 3 (Export Late Build) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Front Impact Sensors Impact Sensor: Description and Operation Front Impact Sensors Front Impact Sensor There are two front impact sensors, one on the left, and one on the right front sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). The right and left front and side impact sensors are identical in construction and calibration and each front impact sensor is secured with two screws. The front impact sensors are secured with two screws to the outboard sides of the right and left front rail tips. The impact sensor housing has an integral connector and two mounting ears, each with a metal sleeve to provide crush protection. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through the headlamp to dash wire harness. The front impact sensors cannot be repaired or adjusted and, if damaged or faulty, they must be replaced. If a front impact sensor is faulty, only the sensor needs to be replaced. If the sensor is damaged or faulty, or if proper tightening torque of the screws that secure the sensor to the bracket cannot be achieved, the sensor and bracket must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Front Impact Sensors > Page 1354 Impact Sensor: Description and Operation Side Impact Sensors Side Impact Sensor Side Impact Sensor Location Three side impact sensors are used on each side of the vehicle. These sensors are mounted remotely from the bi-directional safing sensor that is internal to the Occupant Restraint Controller (ORC). The side and front impact sensors are identical in construction and calibration and each impact sensor is secured with two screws. Each side impact sensor is secured with two screws. The first row side impact sensor is located in the B-pillar, just above the front seat belt retractor. The second row side impact sensor is located in the sliding door opening, in the lower door track area. The third row side impact sensor is located behind the quarter trim panel, above the rear tire wheel well, between the C and D-pillars. The impact sensor housing has an integral connector. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a connector of the body harness. The side impact sensors cannot be repaired or adjusted. If damaged or faulty, they must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor Impact Sensor: Service and Repair Front Impact Sensor REMOVAL. The right and left front impact sensors are mounted identically on the front rail tips. 1. Open hood, disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG SYSTEM OR COMPONENT SERVICE. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, PERSONAL INJURY OR DEATH. 2. Hoist vehicle. Front Impact Sensor Remove/Install 3. Disconnect electrical connector. 4. Remove the two screws attaching front impact sensor to outer rails. 5. Remove sensor from vehicle. INSTALLATION 1. Position sensor in vehicle. 2. Install the two retaining screws to the impact sensor. Torque screws to 7 Nm (62 in. lbs.). 3. Connect electrical connector. 4. Lower vehicle from hoist. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. 5. Verify vehicle and system operation. 6. Close hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor > Page 1357 Impact Sensor: Service and Repair Side Impact Sensors B-Pillar Mounted REMOVAL The right and left front row side impact sensors, are mounted identically, on opposite sides of the vehicle, in the b-pillar. 1. Open hood, disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG COMPONENT SERVICE. PERSONAL INJURY OR DEATH MAY RESULT. 2. Remove the B-pillar lower trim for the side of the vehicle that you are replacing the side impact sensor. Front Row Side Impact Sensor And Bracket 3. Disconnect the electrical connector from the impact sensor. 4. Remove the four retaining screws to the impact sensor bracket. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor > Page 1358 Front Row Side Impact Sensor/Bracket 5. Remove impact sensor from vehicle. INSTALLATION 1. Position sensor bracket in vehicle. 2. Install the four retaining screws to the impact sensor bracket. Torque screws to 7 Nm (62 in. lbs.). 3. Connect the electrical connector. 4. Install the B-pillar lower trim for the side of the vehicle that you are replacing the side impact sensor. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. 5. Verify vehicle and system operation. 6. Close hood. Sliding Door Opening Mounted REMOVAL The right and left second row side impact sensors, are mounted identically, on opposite sides of the vehicle, in the sliding door opening lower rear where the lower roller arm mounts in the lower door track. 1. Open hood, disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG COMPONENT SERVICE. PERSONAL INJURY OR DEATH MAY RESULT. 2. Open sliding door to the fullest open position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor > Page 1359 2nd Row Side Impact Sensor 3. Remove the two retaining screws to the impact sensor. 4. Disconnect the electrical connector from the impact sensor and remove from vehicle. INSTALLATION 1. Connect electrical connector. 2. Position sensor in vehicle. 3. Install the two retaining screws to the impact sensor. Torque screws to 7 Nm (62 in. lbs.). WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. 4. Verify vehicle and system operation. 5. Close hood. Quarter Panel Mounted REMOVAL 1. Open hood, disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG COMPONENT SERVICE. PERSONAL INJURY OR DEATH MAY RESULT. 2. Remove the quarter trim panel for the side of the vehicle that you are replacing the side impact sensor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor > Page 1360 3rd Row Side Impact Sensor 3. Remove the two retaining screws to the impact sensor. 4. Disconnect the electrical connector from the impact sensor and remove from vehicle. INSTALLATION 1. Position sensor in vehicle. 2. Connect electrical connector. 3. Install the two retaining screws to the impact sensor. Torque screws to 7 Nm (62 in. lbs.). 4. Install the quarter trim panel for the side of the vehicle that you are replacing the side impact sensor. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. 5. Verify vehicle and system operation. 6. Close hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1364 Seat Belt Buckle Switch: Diagrams Driver Seat Belt Switch Passenger Seat Belt Switch (Early Build Occupant Sensing) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Tension Sensor > Component Information > Description and Operation Seat Belt Tension Sensor: Description and Operation Belt Tension Sensor Belt Tension Sensor Location Vehicles equipped with the Occupant Classification System (OCS) include a belt tension sensor. This sensor is integral to the passenger side front seat belt lower anchor which is secured to the lower B-pillar, on the passenger side. The belt tension sensor consists of a molded plastic housing, a metal seat belt anchor loop, and a short pigtail wire. The electronic circuitry of the belt tension sensor is concealed and protected within the molded plastic housing. The belt tension sensor cannot be repaired and, if faulty or damaged, the entire passenger side front seat belt and retractor unit must be replaced. The belt tension sensor is designed to sense the relative cinch load applied to the passenger side front seat belt, which provides a logic input to the microprocessor of the Occupant Classification Module (OCM). When a load is applied to the seat belt, the changes in the load are measured by the belt tension sensor through the seat belt lower anchor. As the load changes, the circuitry of the belt tension sensor changes the output voltage of the sensor. The belt tension sensor receives a nominal five volts and a ground from the OCM. The OCM then monitors the belt tension sensor output voltage. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Tension Sensor > Component Information > Description and Operation > Page 1368 WARNING: DO NOT CONNECT THE BATTERY BEFORE PERFORMING THE OCS VERIFICATION TEST USING THE SCAN TOOL AND THE APPROPRIATE DIAGNOSTIC INFORMATION. PERSONAL INJURY OR DEATH MAY OCCUR. For further diagnosis and testing of the belt tension sensor, the OCM, and related occupant classification system components, use a scan tool and the appropriate diagnostic information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams Seat Occupant Sensor: Diagrams Passenger Seat Weight Sensor Occupant Classification Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams Passenger Seat Weight Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Page 1375 Seat Sensor/Switch: Description and Operation Seat Weight Bladder And Pressure Sensor - Typical Vehicles equipped with the Occupant Classification System (OCS) have a seat weight bladder and pressure sensor unit that is integral to the passenger front seat cushion. The bladder is sandwiched between the seat cushion pan and seat cushion foam. The bladder consists of two rectangular sheets of an elastomeric material and a molded plastic elbow fitting. The two sheets of material are sealed together around their perimeter and heat staked to each other at numerous regular points within their field. The elbow fitting is sealed to a small round hole in the lower surface of the bladder and is pointed downward where it passes through a clearance hole in the insulator pad and extends to just below the seat cushion. The bladder is then filled with a silicone fluid to become a pliable, quilted membrane. Under the seat cushion a short tube is securely clamped at one end to the bladder nipple, and at the other end to a nipple on the electronic pressure sensor. The sensor housing features an integral mount that snaps over a tab integral to the stamped steel Occupant Classification Module (OCM) mounting bracket welded to the underside of the passenger front seat cushion frame. The seat weight bladder and pressure sensor cannot be adjusted or repaired. The components of the passenger front seat cushion of a vehicle equipped with the OCS including the cushion frame, seat weight bladder and pressure sensor, seat cushion foam, wire harness and the OCM are serviced only as a factory-calibrated, assembled and tamper-evident unit. Only the OCM and the seat cushion trim are available for separate service replacement. Once a service replacement package has been installed in a vehicle, the OCM can thereafter be serviced only by replacing the entire passenger front seat cushion unit with another complete service replacement package. The seat weight bladder and pressure sensor unit is designed to sense the relative weight of a load applied to the passenger front seat cushion, which provides a logic input to the microprocessor of the Occupant Classification Module (OCM). When a load is applied to the seat cushion, fluid within the bladder becomes pressurized. These changes in bladder fluid pressure are measured by the pressure sensor under the seat cushion through the bladder tube. As the pressure within the bladder changes, the circuitry of the pressure sensor changes the output voltage of the sensor. The pressure sensor receives a nominal five volts and a ground through hard wired circuits from the OCM. The OCM then monitors the pressure sensor output voltage on the Programmable Communication Interface (PCI) data bus circuit. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Specifications Specifications - Battery Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Specifications > Page 1380 Battery Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Specifications > Page 1381 Battery Temperature Sensor: Description and Operation (NGC Vehicles) The PCM incorporates a Battery Temperature Sensor (BTS) on its circuit board. The PCM uses the temperature of the battery area to control the charge system voltage. This temperature, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as temperature around the battery increases. For vehicles with 1.6L engine, there is no physical battery temp sensor in place to detect battery temp. Rather, an algorithm built in PCM is employed to predict battery temp using inlet air temp, vehicle speed, and coolant temp, among other signals. The PCM maintains the optimal output of the generator by monitoring battery voltage and controlling it to a range of 13.5 - 14.7 volts based on battery temperature. The system target voltage is 13.5 - 14.7 volts. However the actual voltage go below this during heavy electrical loads and generator speeds. Also the actual voltage can be lower than the target voltage between the battery and the battery voltage sense circuit, approximately 0.2 - 0.3 volts. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20°F. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Specifications > Page 1382 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor is not serviced separately. If replacement is necessary, the PCM must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Right Side Kick Panel RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation KEY/LOCK CYLINDER DESCRIPTION The lock cylinder is inserted in the end of the housing opposite the ignition switch. OPERATION The ignition key rotates the cylinder to 5 different detents (Fig. 30): Accessory - Off (lock) - Unlock - On/Run - Start Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 1390 Ignition Switch Lock Cylinder: Service and Repair Key/Lock Cylinder REMOVAL 1. Disconnect negative cable from battery. 2. Remove steering column cover retaining screws. 3. Remove screws holding steering column shrouds and remove lower shroud. 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab on the bottom of the lock housing and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position (Fig. 31). 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6. Install steering column cover. 7. Connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The use of tire sealants is strictly prohibited for vehicles equipped with the Tire Pressure Monitoring system. Tire sealants can clog tire pressure sensors. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. CAUTION: Any time a sensor is to be installed in a wheel, a new seal and washer must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 1396 Tire Pressure Sensor: Description and Operation SENSOR - TPM DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor is mounted to each wheel in place of the traditional tire valve stem (Fig. 18). Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency (Fig. 18). The TPM sensors are designed for original style factory wheels. Do not attempt to install a tire pressure sensor in an aftermarket wheel. The serviceable components of the tire pressure sensor are (Fig. 19): Sensor-To-Wheel Seal and Metal Washer - Valve Stem Cap - Valve Stem Core - Valve Stem Nut Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 1397 The valve stem caps and cores used are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. OPERATION The battery operated tire pressure sensors lay dormant (Park Mode), then wake and start transmitting (Drive Mode) when the vehicle first reaches speeds over 15 mph (24 km/h). Once the wheels stop rotating for a period of approximately 20 minutes, the sensors shut down until again awaken. Although not transmitting as when in Drive Mode, while in Park Mode, the sensors still transmit approximately once every 13 hours to let the receiver know air pressure status at that time. Using an RF signal, each sensor transmits tire pressure data approximately once every minute. Each sensor's (transmitter) broadcast is uniquely coded so that the Sentry Key Remote Entry Module (SKREEM) can monitor the state of each of the sensors on the four rotating road wheels. The SKREEM automatically learns and stores the sensor's ID while driving after a sensor has been replaced. There is no formal retraining procedure necessary. For additional information, refer to appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 1398 Tire Pressure Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TIRE PRESSURE SENSOR NOTE: Tire pressure may increase from 2 to 6 psi (14 to 41 kPa) during normal driving conditions. Do NOT reduce this normal pressure build up. When diagnosing a tire pressure issue, always check air pressure in the tires first with a known accurate air gauge. Adjust air pressure as necessary to that listed on the Tire Inflation Pressure Label (Placard) provided with the vehicle (usually applied to the driver's side B-pillar). After adjusting air pressure in a tire, allow approximately two minutes for the message or indicator lamp to go out. Check the tire pressure indicator lamp in the instrument cluster. If the lamp is illuminating continuously, proceed as listed. If the indicator lamp is flashing on/off three times, once every ten minutes, there is a system fault detected. Refer to the appropriate diagnostic information. If air pressure in any tire is low, inspect all the tires for leaks. A water "dunk tank" or other water test may be used to check for a leak around the sensor as long as any water at the valve core is removed once the procedure is completed. The water can be easily expelled from the core area by pushing in on the core for several seconds, allowing escaping air to drive out any moisture. Reinflate the tire as necessary. Always make sure the original valve stem cap is securely installed to keep moisture out of the sensor. If the gauge-read pressure in the tires does not indicate a tire pressure issue, refer to the appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 1399 Tire Pressure Sensor: Service and Repair TIRE PRESSURE SENSOR REMOVAL 1. Remove tire and wheel assembly from vehicle. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 2. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor. That includes both front and rear beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool at the valve stem ± 10° (Fig. 20), then proceed to dismount the tire from the wheel. Use this process on both the upper and lower tire beads. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 1400 3. Remove sensor nut retaining sensor to wheel (Fig. 21). While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 4. Remove sensor from wheel (Fig. 21). INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal and metal washer at base of valve stem to ensure proper sealing (Fig. 22). 1. Wipe area clean around sensor/valve stem mounting hole in wheel. Make sure surface of wheel is not damaged. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 1401 CAUTION: To avoid damaging sensor antenna strap (Fig. 23), hold pressure against rear of metal valve stem (Fig. 24) while sensor is inserted through wheel mounting hole and nut is installed. 2. Insert sensor through wheel as shown keeping pressure against rear of metal valve stem. (Fig. 24). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) by hand (Fig. 24). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 1402 NOTE: Before tightening sensor nut, push downward on sensor housing in an attempt to make it flush with interior contour of wheel (Fig. 25). 4. While holding sensor in position, tighten sensor nut to 6.5 Nm (58 inch lbs.) torque. CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 inch lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function, however, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem approximately 210° from the head of the changer in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire (Fig. 26). Use this procedure on both the upper and lower tire beads. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 1403 b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem is approximately 210° from the head of the changer in a clockwise direction from the mounting end of the tool (Fig. 27) Make sure the sensor is clear of the lower bead breaker area to avoid damaging the sensor when the breaker rises (Fig. 27). Rotate the tool in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install wheel and tire assembly on vehicle. 8. Drive vehicle for a minimum of five minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time the system will learn the new sensor ID code and will clear any DTCs automatically. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Testing and Inspection > Pressure Switch States Pressure Switch States Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Testing and Inspection > Pressure Switch States > Page 1411 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR Sensor, Transmission Range Sensor ...................................................................................................................................................... 5 Nm (45 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 1417 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1418 Transmission Range Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 337). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 338). OPERATION The Transmission Range Sensor (TRS) (Fig. 337) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 1421 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 338) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 1422 Transmission Position Switch/Sensor: Description and Operation 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 303). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM/TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 304). OPERATION The Transmission Range Sensor (TRS) (Fig. 303) communicates Shift Lever Position (SLP) to the PCM/TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the PCM/TCM receives from four sense circuits. The PCM/TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the PCM/TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 1423 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 304) that the PCM/TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the PCM/TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the PCM/TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 1424 Transmission Position Switch/Sensor: Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle Transmission Position Switch/Sensor: Service and Repair 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 305). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 305) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 1427 Transmission Position Switch/Sensor: Service and Repair 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 339). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 339) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 1428 Transmission Position Switch/Sensor: Service and Repair 41TE REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 343). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 343) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications 41TE - Automatic Transmission Sensor, Input Speed ............................................................................................................................ .................................................... 27 Nm (20 ft. lbs.) Sensor, Output Speed ...................................... ........................................................................................................................................ 27 Nm (20 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 1434 Transmission Speed Sensor: Connector Locations Transmission Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 1435 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 1436 Transmission Speed Sensor: Diagrams Input Speed Sensor Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle Transmission Speed Sensor: Description and Operation 40TE Automatic Transaxle Speed Sensor Input INPUT SPEED SENSOR DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case. The Input Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 1439 The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as input shaft rpm. The PCM/TCM compares the input speed signal with output speed signal to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The PCM/TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Speed Sensor Output OUTPUT SPEED SENSOR DESCRIPTION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 1440 The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case. The Output Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as output shaft rpm. The PCM/TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation Vehicle Speed Signal The vehicle speed signal is taken from the Output Speed Sensor. The PCM converts this signal into a pulse per mile and sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 1441 Transmission Speed Sensor: Description and Operation 41TE Automatic Transmission Input Speed Sensor INPUT SPEED SENSOR DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case. The Input Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 1442 The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as input shaft rpm. The PCM/TCM compares the input speed signal with output speed signal to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The PCM/TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Output Speed Sensor OUTPUT SPEED SENSOR DESCRIPTION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 1443 The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case. The Output Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as output shaft rpm. The PCM/TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation Vehicle Speed Signal The vehicle speed signal is taken from the Output Speed Sensor. The PCM converts this signal into a pulse per mile and sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle Transmission Speed Sensor: Service and Repair 40TE Automatic Transaxle Input Speed Sensor SPEED SENSOR INPUT REMOVAL 1. Disconnect battery negative cable. 2. Disconnect input speed sensor connector (Fig. 284). 3. Unscrew and remove input speed sensor (Fig. 285). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 1446 4. Inspect speed sensor o-ring (Fig. 286) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 286). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.) (Fig. 285). 3. Connect speed sensor connector (Fig. 284). 4. Connect battery negative cable. Output Speed Sensor SPEED SENSOR OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector (Fig. 290). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 1447 4. Unscrew and remove output speed sensor (Fig. 291). 5. Inspect speed sensor o-ring (Fig. 292) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 292). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector (Fig. 290). 4. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 1448 Transmission Speed Sensor: Service and Repair 41TE Automatic Transmission Input Speed Sensor SPEED SENSOR INPUT REMOVAL 1. Disconnect battery negative cable. 2. Disconnect input speed sensor connector (Fig. 284). 3. Unscrew and remove input speed sensor (Fig. 285). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 1449 4. Inspect speed sensor o-ring (Fig. 286) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 286). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.) (Fig. 285). 3. Connect speed sensor connector (Fig. 284). 4. Connect battery negative cable. Output Speed Sensor SPEED SENSOR OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector (Fig. 290). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 1450 4. Unscrew and remove output speed sensor (Fig. 291). 5. Inspect speed sensor o-ring (Fig. 292) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 292). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector (Fig. 290). 4. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 1454 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Rear Defogger Switch > Component Information > Description and Operation Rear Defogger Switch: Description and Operation A/C Heater Control - Typical The switch for the rear window defogger (EBL) system is integrated into the A/C-heater control, which is located in the center of the instrument panel. When the rear window defogger switch is activated, the A/C-heater control requests the front control module (FCM) to operate the rear window defogger (EBL) relay. When the EBL relay is activated, current is directed to the rear defogger grid lines and the heated side view mirrors (if equipped). The grid lines heat the glass to help clear the surface of fog or frost. An LED indicator will illuminate when the rear window defogger switch is activated. When the switch is activated, the A/C-heater control requests the front control module (FCM) to operate the rear window defogger (EBL) relay. The EBL relay controls the current flow to the grids of the rear window defogger and to the heated side view mirrors, when equipped. NOTE: The EBL system turns off automatically after 10 minutes of initial operation. Each following activation cycle of the EBL system will last five minutes. The EBL system will initially be on for approximately ten minutes or until the rear window defogger switch or the ignition switch is turned off. After the initial time interval has expired, if the defogger switch is turned On again during the same ignition cycle, the EBL system will automatically turn off after about five minutes. The rear window defogger switch and the rear window defogger LED indicator cannot be repaired and, if faulty or damaged, the A/C-heater control must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Passenger Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1462 Power Window Switch: Diagrams Driver Power Window Switch (LHD Except Low Line) Driver Power Window Switch (LHD Low Line) Driver Power Window Switch (RHD) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1463 Passenger Power Window Switch Power Window Switch (LHD Lowline) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1464 Power Window Switch: Testing and Inspection 1. Remove the desired switch to be tested from the door trim panel. Driver's side (master) or passenger side. Power Window Master Switch Connector 2. Using an ohmmeter, Test driver door switch for continuity as described. Power Window Master Switch Test 3. If the result are not OK, replace the driver side window lift switch. * MUST TEST WITH B+ ON PIN 9 AND GROUND ON PIN 13 FOR CONTINUITY BETWEEN PINS 11 AND 6 Passenger Door Power Window Switch 4. Test passenger door switch for continuity as described. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1465 Passenger Window Switch Test 5. If the results are not OK, replace the switch. The power window master switch has a Auto-Down feature. The switch is equipped with two detent positions when actuating the power window OPEN. The first detent position allows the window to roll down and stop when the switch is released. The second detent position actuates an integral express roll down relay that rolls the window down after the switch is released. When the express down circuit senses stall current (window has reached end of down travel), the switch will turn current off to the motor. The AUTO feature can be cancelled by actuating the switch UP or DOWN while window is in motion. If the electronic circuit in the switch fails to detect a stall current, the auto down circuit will time out within 9 to 13 seconds. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 1466 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Window Switch 2. Using a trim stick, start at the bottom of the switch and bezel assembly and pry up to remove the switch and bezel assembly from the door trim panel. 3. Unlatch the locking tab on the harness side connector of the switch. 4. Disconnect wire harness connectors from switch. INSTALLATION 1. Reconnect wire harness connector to switch. 2. Insert switch into door trim panel and press into place. 3. Reconnect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1471 Washer Fluid Level Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1472 Washer Fluid Level Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Hoist and support vehicle on hoist or jack stands. 3. If necessary, remove the right front wheel and tire assembly. 4. Disconnect the right front wheelhouse splash shield and move aside. 5. Drain washer fluid from the reservoir and into a suitable clean container. This can be done by disconnecting the windshield washer hose from the front (outboard) washer pump port allowing the washer fluid to drain into a container through a temporary jumper hose connected to the front washer pump. 6. Disconnect the electrical body harness connector to the the fluid level sensor. Slide the red lock on the connector to the release position, then, depress the black tab and pull the connector off the sensor. 7. Remove the sensor from reservoir by using a side foot to gently pry the sensor from the body of the reservoir. Do not damage the reservoir/sensor sealing surface or puncture reservoir during removal. CAUTION: To avoid damage to the sensor, assure the reservoir is in an upright position before removing the sensor from the reservoir. Do not rotate the sensor during removal. INSTALLATION 1. Use a new grommet when installing a new sensor assembly. 2. Assure that the flat of the sensor is aligned under the ridge of the reservoir and that the sensor connector is facing down in the fully seated position. This will allow for proper operation of the sensor float switch. 3. Connect the electrical body harness connectors to the fluid level sensor. Slide the red lock on the connector to the closed or locked position. 4. Assure that washer hose is properly routed to prevent pinching and possible inoperative washers. 5. Connect the left right front wheelhouse splash shield and move aside. 6. Install the right front wheel and tire assembly. 7. lower vehicle from hoist or jack stands. 8. Connect the battery negative cable. 9. Verify system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation Windshield Washer Switch: Description and Operation Instrument Panel Center Bezel On Automatic Temperature Control (ATC) vehicles only, the rear window wiper/washer switches are located on the center bezel with the hazard and heated seat switches. They are not serviceable separately from the hazard and heated seat switches. If defective, the entire switch assembly must be replaced. Rear Wiper/Washer Switch Location On Manual Temperature Control (MTC) vehicles only, the rear window wiper/washer switch is located on the HVAC control head attached to the center bezel. They are not serviceable separately from the control head. If found faulty, the entire MTC head must be replaced. When rear wiper operation is required, the BCM will provide ignition ON voltage to the rear wiper motor. When the wiper switch is turned OFF, the BCM provides circuit ground to operate the motor until the wipe cycle is complete and the wiper arm returns to the base of the rear window. The rear wiper/washer switch only offers an intermittent rear wiper mode. The wiper motor will cycle every 7 seconds. The intermittent delay time is also adjusted based upon vehicle speed. With the vehicle traveling greater than 50 mph, the cycle changes to every 5 seconds. When rear washer is requested by depressing and holding down the switch, the BCM then provides a ground for the rear washer motor. Until the switch is released, the motor will be in a continuous wipe mode, then return to an intermittent wipe mode. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 1476 Windshield Washer Switch: Testing and Inspection Wiper/Washer Switch Resistance 1. Remove the multi-function switch. 2. Using an ohmmeter check resistance readings between switch pins. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation Wiper Switch: Description and Operation Instrument Panel Center Bezel On Automatic Temperature Control (ATC) vehicles only, the rear window wiper/washer switches are located on the center bezel with the hazard and heated seat switches. They are not serviceable separately from the hazard and heated seat switches. If defective, the entire switch assembly must be replaced. Rear Wiper/Washer Switch Location On Manual Temperature Control (MTC) vehicles only, the rear window wiper/washer switch is located on the HVAC control head attached to the center bezel. They are not serviceable separately from the control head. If found faulty, the entire MTC head must be replaced. When rear wiper operation is required, the BCM will provide ignition ON voltage to the rear wiper motor. When the wiper switch is turned OFF, the BCM provides circuit ground to operate the motor until the wipe cycle is complete and the wiper arm returns to the base of the rear window. The rear wiper/washer switch only offers an intermittent rear wiper mode. The wiper motor will cycle every 7 seconds. The intermittent delay time is also adjusted based upon vehicle speed. With the vehicle traveling greater than 50 mph, the cycle changes to every 5 seconds. When rear washer is requested by depressing and holding down the switch, the BCM then provides a ground for the rear washer motor. Until the switch is released, the motor will be in a continuous wipe mode, then return to an intermittent wipe mode. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Failed Park Switch Wiper Switch: Testing and Inspection Failed Park Switch If the wiper park switch has failed, the windshield wipers will operate as follows: - SWITCH OFF - Wipers stop in current location regardless of the park signal. - INTERMITTENT MODE - Wipers operate continuously or at low speed for one or more extra wipes. - LOW SPEED - Wipers operate at low speed. - HIGH SPEED - Wipers operate at high speed. - WIPE AFTER WASH - Wipers operate at low speed in any mode setting. Wipers operate only while the wash button is depressed with switch in the OFF mode and wipers stop in mid-cycle when button is released. Wiper System Diagnosis Part 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Failed Park Switch > Page 1482 Wiper System Diagnosis Part 2 The windshield wiper park switch and circuit is monitored by the BCM. The park switch and circuit can be tested using the WIPER SYSTEM DIAGNOSIS table. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Failed Park Switch > Page 1483 Wiper Switch: Testing and Inspection Front Wiper/Washer Switch Wiper/Washer Switch Resistance 1. Remove the multi-function switch. 2. Using an ohmmeter check resistance readings between switch pins. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ............................... 400 kPa ± 34 kPa (58 psi ± 5 psi) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check Fuel Pressure: Testing and Inspection Fuel Delivery Check Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 1494 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 1495 Test 7 - 9 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specs - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump module - Fuel delivery system operation - Fuel pump relay fused B+ circuit - (A141) fuel pump relay output circuit open - (Z1) fuel pump ground circuit open/high resistance - Fuel pump module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 1496 Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test Test 1 - 2 SYMPTOM CHECKING FUEL PRESSURE LEAK DOWN POSSIBLE CAUSES - Checking fuel pressure - Fuel pump module - Checking fuel leak down Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications The cylinders are numbered from the front of the engine to the rear. The front cylinder bank is numbered 2, 4, 6. The rear cylinder bank is numbered 1, 3, 5. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 1501 Firing Order: Mechanical Specifications Firing Order 1-2-3-4-5-6 .............................................................................................................................................................. ......................................... Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations The cylinders are numbered from the front of the engine to the rear. The front cylinder bank is numbered 2, 4, 6. The rear cylinder bank is numbered 1, 3, 5. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set Ignition Cable: Customer Interest Engine Controls/Ignition - MIL ON/Misfire DTC's Set NUMBER: 18-018-04 GROUP: Vehicle Performance DATE: April 27, 2004 THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD JUNE, 2004. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303, P0304, P0305, P0306 OVERVIEW: This bulletin involves replacing the spark plugs, ignition wires and if necessary, reprogramming the Powertrain Control Module with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004 (MDH 0402XX). SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC's: ^ P0300-MULTIPLE CYLINDER MISFIRE ^ P0301-CYLINDER # 1 MISFIRE ^ P0302-CYLINDER # 2 MISFIRE ^ P0303-CYLINDER # 3 MISFIRE ^ P0304-CYLINDER # 4 MISFIRE ^ P0305-CYLINDER # 5 MISFIRE ^ P0306-CYLINDER # 6 MISFIRE DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform Repair Procedure 1 and if necessary, Repair Procedure 2. If an "Authorized Modification Label" is present and states that Service Bulletin 18-016-04 has been performed, it is not necessary to perform Repair Procedure 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 1514 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE 1: Replace spark plugs and ignition cables 1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service information available in TechCONNECT or the Town & Country and Caravan service manual (publication no. 81-370-04062CD), page 8I-10. 2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2. If Service Bulletin 18-016-04 has been performed, no further action is necessary. REPAIR PROCEDURE 2: Flash Reprogram PCM NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 1515 c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select 'Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 1516 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set Ignition Cable: All Technical Service Bulletins Engine Controls/Ignition - MIL ON/Misfire DTC's Set NUMBER: 18-018-04 GROUP: Vehicle Performance DATE: April 27, 2004 THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD JUNE, 2004. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303, P0304, P0305, P0306 OVERVIEW: This bulletin involves replacing the spark plugs, ignition wires and if necessary, reprogramming the Powertrain Control Module with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004 (MDH 0402XX). SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC's: ^ P0300-MULTIPLE CYLINDER MISFIRE ^ P0301-CYLINDER # 1 MISFIRE ^ P0302-CYLINDER # 2 MISFIRE ^ P0303-CYLINDER # 3 MISFIRE ^ P0304-CYLINDER # 4 MISFIRE ^ P0305-CYLINDER # 5 MISFIRE ^ P0306-CYLINDER # 6 MISFIRE DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform Repair Procedure 1 and if necessary, Repair Procedure 2. If an "Authorized Modification Label" is present and states that Service Bulletin 18-016-04 has been performed, it is not necessary to perform Repair Procedure 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 1522 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE 1: Replace spark plugs and ignition cables 1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service information available in TechCONNECT or the Town & Country and Caravan service manual (publication no. 81-370-04062CD), page 8I-10. 2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2. If Service Bulletin 18-016-04 has been performed, no further action is necessary. REPAIR PROCEDURE 2: Flash Reprogram PCM NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 1523 c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select 'Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 1524 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 1525 Ignition Cable: Description and Operation SPARK PLUG CABLE Spark Plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the ignition coil pack to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Check the spark plug cable connections for good contact at the coil, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean Spark Plug cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. The spark plug cables and spark plug boots are made from high temperature materials. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set Spark Plug: Customer Interest Engine Controls/Ignition - MIL ON/Misfire DTC's Set NUMBER: 18-018-04 GROUP: Vehicle Performance DATE: April 27, 2004 THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD JUNE, 2004. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303, P0304, P0305, P0306 OVERVIEW: This bulletin involves replacing the spark plugs, ignition wires and if necessary, reprogramming the Powertrain Control Module with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004 (MDH 0402XX). SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC's: ^ P0300-MULTIPLE CYLINDER MISFIRE ^ P0301-CYLINDER # 1 MISFIRE ^ P0302-CYLINDER # 2 MISFIRE ^ P0303-CYLINDER # 3 MISFIRE ^ P0304-CYLINDER # 4 MISFIRE ^ P0305-CYLINDER # 5 MISFIRE ^ P0306-CYLINDER # 6 MISFIRE DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform Repair Procedure 1 and if necessary, Repair Procedure 2. If an "Authorized Modification Label" is present and states that Service Bulletin 18-016-04 has been performed, it is not necessary to perform Repair Procedure 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 1534 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE 1: Replace spark plugs and ignition cables 1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service information available in TechCONNECT or the Town & Country and Caravan service manual (publication no. 81-370-04062CD), page 8I-10. 2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2. If Service Bulletin 18-016-04 has been performed, no further action is necessary. REPAIR PROCEDURE 2: Flash Reprogram PCM NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 1535 c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select 'Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 1536 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set Spark Plug: All Technical Service Bulletins Engine Controls/Ignition - MIL ON/Misfire DTC's Set NUMBER: 18-018-04 GROUP: Vehicle Performance DATE: April 27, 2004 THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD JUNE, 2004. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303, P0304, P0305, P0306 OVERVIEW: This bulletin involves replacing the spark plugs, ignition wires and if necessary, reprogramming the Powertrain Control Module with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004 (MDH 0402XX). SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC's: ^ P0300-MULTIPLE CYLINDER MISFIRE ^ P0301-CYLINDER # 1 MISFIRE ^ P0302-CYLINDER # 2 MISFIRE ^ P0303-CYLINDER # 3 MISFIRE ^ P0304-CYLINDER # 4 MISFIRE ^ P0305-CYLINDER # 5 MISFIRE ^ P0306-CYLINDER # 6 MISFIRE DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform Repair Procedure 1 and if necessary, Repair Procedure 2. If an "Authorized Modification Label" is present and states that Service Bulletin 18-016-04 has been performed, it is not necessary to perform Repair Procedure 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 1542 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE 1: Replace spark plugs and ignition cables 1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service information available in TechCONNECT or the Town & Country and Caravan service manual (publication no. 81-370-04062CD), page 8I-10. 2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2. If Service Bulletin 18-016-04 has been performed, no further action is necessary. REPAIR PROCEDURE 2: Flash Reprogram PCM NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 1543 c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select 'Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 1544 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications Spark Plug Resistance - 3.3/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 1547 Spark Plug: Mechanical Specifications Spark Plug - 3.3L/3.8L Torque Spark Plug Torque ............................................................................................................................... ................................................ 13 ft. lbs. (17.5 N.m) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1548 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. .................................................................RE14PLP5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1549 Spark Plug: Description and Operation STANDARD 4 CYLINDER All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Refer to Specifications for gap and type of spark plug. PLATINUM PLUGS The V6 engines use platinum resistor spark plugs. They have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. For spark plug identification and specifications, refer to Specifications. Do not use man ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Platinum Pads Setting Spark Electrode Gap When the spark plugs use a single or double platinum tips and they have a recommended service life of 100,000 miles for normal driving conditions per Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1550 schedule A. The spark plugs have a recommended service life of 75,000 miles for severe driving conditions per schedule B. A thin platinum pad is welded to both or just the center electrode end(s) as shown. Extreme care must be used to prevent spark plug cross threading, mis-gapping and ceramic insulator damage during plug removal and installation. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1551 Spark Plug: Service and Repair REMOVAL When replacing the spark plugs and spark plug cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. Always remove cables by grasping at the boot, rotating the boot 1/2 turn, and pulling straight back in a steady motion. 1. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. 2. Remove the spark plug using a quality socket with a foam insert. 3. Inspect the spark plug condition. INSTALLATION When replacing the spark plugs and spark plug cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. 1. Coat threads of spark plug with anti-seize. Be sure not to get anti-seize ANYWHERE BUT ON THE THREADS OF THE SPARK PLUG as shown. 2. To avoid cross threading, start the spark plug into the cylinder head by hand. 3. Tighten spark plugs to 17.5 N.m (13 ft. lbs.) torque. 4. Install spark plug cables over spark plugs. A click will be heard and felt when the cable properly attaches to the spark plug. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Cylinder Compression Pressure Cylinder Compression Pressure Minimum Compression Pressure 100 psi Maximum Variation Between Cylinders 25 % Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1555 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Remove the Auto Shutdown (ASD) relay from the PDC. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gauge adaptor Special Tool 8116 or the equivalent, into the # 1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer (Special Tool CH7059) with cable adaptors to the DRBIII. 7. Crank engine until maximum pressure is reached on gauge. Record this pressure as # 1 cylinder pressure. 8. Repeat the previous step for all remaining cylinders. 9. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 10. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 11. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1562 Drive Belt: Description and Operation DRIVE BELTS DESCRIPTION The drive belts are a Poly-V type belt. Belt widths vary depending on the various engine and accessory packages. Satisfactory performance of these belts depends on belt condition and proper belt tension. OPERATION The accessory drive belts form the link between the engine crankshaft and the engine driven accessories. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1563 Drive Belt: Testing and Inspection ACCESSORY DRIVE BELT Part 1 of 2 Part 2 of 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1564 Drive Belt: Service and Repair DRIVE BELTS REMOVAL 1. Raise vehicle on hoist. Fig.8 2. Remove the drive belt shield (Fig. 8). WARNING: DO NOT ALLOW DRIVE BELT TENSIONER TO SNAP BACK, AS DAMAGE TO TENSIONER AND/OR PERSONAL INJURY COULD RESULT. Fig.9 3. Position a wrench on the belt tensioner lug (Fig. 9). 4. Release belt tension by rotating the tensioner counterclockwise (Fig. 9). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1565 Fig.11 5. Remove the drive belt (Fig. 11). 6. Carefully return tensioner to its relaxed position. CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. INSPECTION Belt replacement under any or all of the following conditions is required: Excessive wear - Frayed cords - Severe glazing Fig.10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 1566 Poly-V Belt system may develop minor cracks across the ribbed side (due to reverse bending). These minor cracks are considered normal and acceptable. Parallel cracks are not (Fig. 10). NOTE: Do not use any type of belt dressing or restorer on Poly-V Belts. INSTALLATION 1. Route and position the drive belt onto all pulleys, except for the crankshaft (Fig. 11). 2. Rotate belt tensioner counterclockwise until belt can be installed onto the crankshaft pulley (Fig. 9). Slowly release belt tensioner. 3. Verify belt is properly routed and engaged on all pulleys. 4. Install drive belt shield (Fig. 8) and lower vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations Cabin Air Filter: Locations Fig.1 Air Filter The Cabin Air Filter access door is located under the instrument panel on the passenger side. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations > Page 1571 Cabin Air Filter: Description and Operation Particulate Air Filter A dust and odor air filter is standard equipment on models equipped with the three zone temperature control systems. The filter element is the same size as the front A/C evaporator to ensure ample filtering capacity. A removable door on the bottom of the front HVAC housing below the glove box provides easy access to the filter element for replacement. The filter should be checked and replaced at least once every 24,000 km (15,000 miles) and checked if heater-A/C system performance seems lower than expected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations > Page 1572 Cabin Air Filter: Service and Repair REMOVAL Air Filter Door - Typical 1. Locate the air filter door on the bottom of the lower front HVAC housing just outboard of the passenger side of the instrument panel center stack. 2. Slide the air filter door latch toward the rear of the vehicle until it engages the opened stop on the door. 3. Pull the air filter door straight downward to disengage it from the air filter opening of the HVAC housing. 4. Use your fingers to reach through the air filter opening of the HVAC housing far enough to grasp the air filter. 5. Pull the air filter straight down and out of the HVAC housing. INSTALLATION NOTE: The particulate air filter is labeled with "Airflow" and an arrow to indicate air flow direction through the filter. This arrow should always be oriented towards the center of the vehicle. Make sure to properly install the particulate air filter. Failure to properly install the filter will result in the need to replace the filter sooner than required by design. 1. Install the filter fully upward into the HVAC housing through the air filter opening with the "Airflow" arrow oriented towards the center of the vehicle. 2. With the latch still positioned against its opened stop, install the air filter door onto the lower HVAC housing air filter opening. 3. Slide the air filter door latch toward the front of the vehicle until it contacts the closed stop on the door. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 40TE Fluid Filter - A/T: Service and Repair 40TE STANDARD PROCEDURE - FLUID AND FILTER SERVICE NOTE: Refer to the maintenance schedules in LUBRICATION and MAINTENANCE, or the vehicle owner's manual, for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: Only fluids of the type labeled leopard ATF+4 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed. FLUID/FILTER SERVICE (RECOMMENDED) 1. Raise vehicle on a hoist. Refer to LUBRICATION and MAINTENANCE for proper procedures. Place a drain container with a large opening, under transaxle oil pan. 2. Remove both engine mount-to-engine crossmember cradle nuts. Using suitable screw jack and wood block, raise engine and transmission slightly to facilitate transaxle oil pan removal and installation. 3. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 4. Install a new filter and o-ring on bottom of the valve body (Fig. 189). 5. Clean the oil pan and magnet. Reinstall pan using new Mopar Silicone Adhesive sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 6. Pour four quarts of Mopar ATF+4 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the lowest mark on the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 40TE > Page 1577 dipstick (Fig. 190). 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). Refer to Fluid Level and Condition Check for the proper fluid fill procedure. 10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE) 1. When performing the fluid suction method, make sure the transaxle is at full operating temperature. 2. To perform the dipstick tube fluid suction method, use a suitable fluid suction device (Vacula TM or equivalent). 3. Insert the fluid suction line into the dipstick tube. NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will ensure complete evacuation of the fluid in the pan. 4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5. Remove the suction line from the dipstick tube. 6. Pour four quarts of Mopar ATF+4 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3mm (1/8 inch) below the lowest mark on the dipstick (Fig. 190). 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). 10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 40TE > Page 1578 Fluid Filter - A/T: Service and Repair 41TE 41TE - Automatic Transmission STANDARD PROCEDURE - FLUID AND FILTER SERVICE NOTE: Refer to the vehicle owner's manual, for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: Only fluids of the type labeled leopard ATF+4 (Automatic Transmission Fluid) Type 9602 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed. FLUID/FILTER SERVICE (RECOMMENDED) 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body (Fig. 212). 4. Clean the oil pan and magnet. Reinstall pan using new Mopar Silicone Adhesive sealant. Tighten oil pan bolts to............19 Nm (165 inch lbs.). 5. Pour four quarts of Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3mm (1/8 inch) below the lowest mark on the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > 40TE > Page 1579 dipstick (Fig. 213). 8. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). Refer to Fluid Level and Condition Check for the proper fluid fill procedure. 9. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE) 1. When performing the fluid suction method, make sure the transaxle is at full operating temperature. 2. To perform the dipstick tube fluid suction method, use a suitable fluid suction device (Vacula or equivalent). 3. Insert the fluid suction line into the dipstick tube. NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will ensure complete evacuation of the fluid in the pan. 4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5. Remove the suction line from the dipstick tube. 6. Pour four quarts of Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick (Fig. 213). 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). 10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Service and Repair Fuel Pump Pickup Filter: Service and Repair REMOVAL 1. Remove fuel pump module. Refer to Fuel Pump Module Removal. Inlet 2. Using a thin straight blade screwdriver, pry back the locking tabs on fuel pump reservoir and remove the strainer. 3. Remove strainer O-ring from the fuel pump reservoir body. 4. Remove any contaminants in the fuel tank by washing the inside of the fuel tank. INSTALLATION 1. Lubricate the strainer O-ring with clean engine oil. 2. Insert strainer O-ring into outlet of strainer so that it sits evenly on the step inside the outlet. 3. Push strainer onto the inlet of the fuel pump reservoir body. Make sure the locking tabs on the reservoir body lock over the locking tangs on the strainer. 4. Install fuel pump module. Refer to Fuel Pump Module Installation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil Filter Attachment Fitting ................................................................................................................. ................................................... 54 Nm (40 ft. lbs.) Oil Filter ............................................................................................................................................... .................................................... 20 Nm (15 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page 1586 Oil Filter: Service and Repair REMOVAL CAUTION: When servicing the oil filter avoid deforming the filter can by installing the remove/install tool band strap against the can-to-base lock seam. The lock seam joining the can to the base is reinforced by the base plate. Fig.105 1. Using suitable oil filter wrench, turn filter counterclockwise to remove from oil filter adapter (Fig. 105). Properly discard used oil filter. INSTALLATION 1. Wipe oil filter adapter base clean and inspect gasket contact surface. 2. Lubricate gasket of new filter with clean engine oil. 3. Install new filter until gasket contacts base (Fig. 105). Tighten filter 1 turn or 20 Nm (15 ft. lbs.). Use filter wrench if necessary. 4. Start engine and check for leaks. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > Recalls for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion Technical Service Bulletin # F01 Date: 060201 Campaign - Rear A/C/Heater Tube Corrosion February 2006 Dealer Service Instructions for: Customer Satisfaction Notification F01 Rear A/C and Heater Tube Corrosion Effective immediately all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 05-028 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2005 (RS) Dodge Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles equipped with rear Heater/Air Conditioning (sales code HBB) and Stow-n-Go seats (sales code CYC) or Stow-N-Go floor pan (sales code CYY or CYV). IMPORTANT: Only the above vehicles sold or currently registered in "salt belt" states (where large amounts of road salt are used for snow and ice removal) are involved. See "Owner Notification and Service Scheduling" section for a list of salt belt states. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The underbody rear A/C and heater tube mounting brackets on about 239,800 of the above vehicles may have insufficient corrosion protection. Excessive corrosion can cause the rear A/C or heater tubes to leak. This may result in either an inoperative A/C system or engine overheating. Engine damage can occur if an overheated engine continues to be driven. Repair The underbody rear A/C and heater tube assembly must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > Recalls for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1596 Parts Information Completion Reporting and Reimbursement DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Only vehicles sold or currently registered in "Salt Belt" states (where large amounts of road salt are used for snow and ice removal) are involved. The Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > Recalls for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1597 following states are "Salt Belt" states: Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the hood. 2. Using an approved refrigerant recovery machine, recover the refrigerant from the air conditioning system. Follow the manufacturers instructions provided with the machine being used. 3. Using a suitable clean container, drain the coolant from the engine cooling system. Save the coolant for reuse. 4. Raise the vehicle on an appropriate hoist. 5. Disconnect the exhaust system from the exhaust hanger rubber isolators and position the exhaust system out of the way. 6. Disconnect the underbody A/C lines from the front liquid and suction line extension tubes (Figure 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > Recalls for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1598 7. Remove the nut that secures the underbody A/C lines to the rear evaporator tapping plate (Figure 2). 8. Disconnect the underbody A/C lines from the evaporator tapping plate. NOTE: The A/C line mounting block may not come loose after removing the retaining nut due to corrosion between the mounting block and the retaining stud. Do not use excessive force to attempt to remove the mounting block from the evaporator. Evaporator damage may occur. Using an air chisel with a flat nose bit, gently pull down on the A/C lines and then lightly rap on the end of the stud with the bit of the air chisel (Figure 3). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > Recalls for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1599 9. Remove the fasteners that secure the four underbody line retaining straps to the vehicles underbody (Figure 4). 10. Remove the fastener that secures the right rear brake line bracket to the underbody (Figure 5). 11. Disconnect the underbody heater tubes at the rear of the vehicle by releasing the insert in the underbody heater tube quick connect fittings and Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > Recalls for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1600 carefully pull downward on the heater tube fitting. CAUTION: Residual coolant will come out of the heater hoses when they are removed. Be prepared to catch the residual coolant in a suitable container. 12. Lower the underbody heater tubes to drain any residual coolant from the tubes. 13. Using spring tension clamp pliers (Blue Point(R) YA9562 or equivalent), compress and slide the clamps off the rubber hoses at the front of the underbody coolant tubes. 14. Disconnect the heater hoses by carefully twisting the hoses back and forth while gently pulling them away from the end of the coolant tubes. 15. Remove and discard the underbody rear A/C and heater tubes. 16. Using locking pliers, remove and discard the stud from the evaporator tapping plate. CAUTION: Failure to replace the stud will cause future A/C tube failure. The new stud has an additional coating to prevent corrosion. 17. Using an E7 Torx(R) socket (Snap-on(R) TLE70A or equivalent), install the new stud provided in the kit into the evaporator tapping plate (Figure 6). Tighten the stud to 80 in. lbs. (9 N.m). 18. Remove the plastic shipping cap on the A/C mounting block and pour 1 oz. of PAG oil (P/N 82300102) into the A/C suction line. Then temporarily reinstall the shipping cap. 19. Position the new line kit under the vehicle and install the fasteners that secure the four retaining straps to the vehicle. Tighten the fasteners to 65 in. lbs. (7 N.m). 20. Position the rear brake line bracket and install the fastener. Tighten the fastener to 250 in. lbs. (28 N.m). 21. Remove and discard the plastic shipping cap from the A/C mounting block and lubricate the new o-ring seals with clean refrigerant oil. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > Recalls for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1601 22 Connect the underbody A/C lines to the rear evaporator tapping plate (Figure 7). 23. Install the new nut/washer, provided in the kit, to secure the underbody A/C line mounting block to the rear evaporator tapping plate (Figure 7). Tighten the nut to 17 ft. lbs. (23 N.m). 24. Remove the plastic shipping caps and lubricate the new o-ring seals for front extension tubes with clean refrigerant oil. 25. Connect the underbody A/C line fittings to the front liquid and suction line extension tubes. Tighten the A/C line brass nuts to 17 ft. lbs. (23 N.m). 26. Connect the rubber hoses at the front of the underbody heater tube hoses to the rear heater extension tubes. 27. Using spring tension clamp pliers (Blue Point® YA9562 or equivalent), compress and slide the clamps that secure the heater hoses over the extension tubes. Release the clamp when it is correctly positioned over the tube. 28. Connect the rear underbody heater quick connect fittings to the rear heater core extension tubes. 29. Place the exhaust system into position and attach the exhaust hanger rubber isolators. 30. Lower the vehicle from the hoist. 31. Using an approved refrigerant evacuation machine, evacuate the A/C system. Follow the manufacturers instructions provided with the machine being used. 32. Refill the engine cooling system using the original coolant removed from the vehicle. 33. Using an approved refrigerant charging machine, charge the A/C system. Follow the manufacturers instructions provided with the machine being used. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > Recalls for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1602 NOTE: Refer to the underhood A/C charge label for the correct amount of refrigerant to install into the A/C system (Figure 8). 34. Remove the A/C charging machine, close the hood and return the vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > Recalls for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1603 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion Technical Service Bulletin # F01 Date: 060201 Campaign - Rear A/C/Heater Tube Corrosion February 2006 Dealer Service Instructions for: Customer Satisfaction Notification F01 Rear A/C and Heater Tube Corrosion Effective immediately all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 05-028 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2005 (RS) Dodge Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles equipped with rear Heater/Air Conditioning (sales code HBB) and Stow-n-Go seats (sales code CYC) or Stow-N-Go floor pan (sales code CYY or CYV). IMPORTANT: Only the above vehicles sold or currently registered in "salt belt" states (where large amounts of road salt are used for snow and ice removal) are involved. See "Owner Notification and Service Scheduling" section for a list of salt belt states. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The underbody rear A/C and heater tube mounting brackets on about 239,800 of the above vehicles may have insufficient corrosion protection. Excessive corrosion can cause the rear A/C or heater tubes to leak. This may result in either an inoperative A/C system or engine overheating. Engine damage can occur if an overheated engine continues to be driven. Repair The underbody rear A/C and heater tube assembly must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1609 Parts Information Completion Reporting and Reimbursement DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Only vehicles sold or currently registered in "Salt Belt" states (where large amounts of road salt are used for snow and ice removal) are involved. The Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1610 following states are "Salt Belt" states: Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the hood. 2. Using an approved refrigerant recovery machine, recover the refrigerant from the air conditioning system. Follow the manufacturers instructions provided with the machine being used. 3. Using a suitable clean container, drain the coolant from the engine cooling system. Save the coolant for reuse. 4. Raise the vehicle on an appropriate hoist. 5. Disconnect the exhaust system from the exhaust hanger rubber isolators and position the exhaust system out of the way. 6. Disconnect the underbody A/C lines from the front liquid and suction line extension tubes (Figure 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1611 7. Remove the nut that secures the underbody A/C lines to the rear evaporator tapping plate (Figure 2). 8. Disconnect the underbody A/C lines from the evaporator tapping plate. NOTE: The A/C line mounting block may not come loose after removing the retaining nut due to corrosion between the mounting block and the retaining stud. Do not use excessive force to attempt to remove the mounting block from the evaporator. Evaporator damage may occur. Using an air chisel with a flat nose bit, gently pull down on the A/C lines and then lightly rap on the end of the stud with the bit of the air chisel (Figure 3). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1612 9. Remove the fasteners that secure the four underbody line retaining straps to the vehicles underbody (Figure 4). 10. Remove the fastener that secures the right rear brake line bracket to the underbody (Figure 5). 11. Disconnect the underbody heater tubes at the rear of the vehicle by releasing the insert in the underbody heater tube quick connect fittings and Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1613 carefully pull downward on the heater tube fitting. CAUTION: Residual coolant will come out of the heater hoses when they are removed. Be prepared to catch the residual coolant in a suitable container. 12. Lower the underbody heater tubes to drain any residual coolant from the tubes. 13. Using spring tension clamp pliers (Blue Point(R) YA9562 or equivalent), compress and slide the clamps off the rubber hoses at the front of the underbody coolant tubes. 14. Disconnect the heater hoses by carefully twisting the hoses back and forth while gently pulling them away from the end of the coolant tubes. 15. Remove and discard the underbody rear A/C and heater tubes. 16. Using locking pliers, remove and discard the stud from the evaporator tapping plate. CAUTION: Failure to replace the stud will cause future A/C tube failure. The new stud has an additional coating to prevent corrosion. 17. Using an E7 Torx(R) socket (Snap-on(R) TLE70A or equivalent), install the new stud provided in the kit into the evaporator tapping plate (Figure 6). Tighten the stud to 80 in. lbs. (9 N.m). 18. Remove the plastic shipping cap on the A/C mounting block and pour 1 oz. of PAG oil (P/N 82300102) into the A/C suction line. Then temporarily reinstall the shipping cap. 19. Position the new line kit under the vehicle and install the fasteners that secure the four retaining straps to the vehicle. Tighten the fasteners to 65 in. lbs. (7 N.m). 20. Position the rear brake line bracket and install the fastener. Tighten the fastener to 250 in. lbs. (28 N.m). 21. Remove and discard the plastic shipping cap from the A/C mounting block and lubricate the new o-ring seals with clean refrigerant oil. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1614 22 Connect the underbody A/C lines to the rear evaporator tapping plate (Figure 7). 23. Install the new nut/washer, provided in the kit, to secure the underbody A/C line mounting block to the rear evaporator tapping plate (Figure 7). Tighten the nut to 17 ft. lbs. (23 N.m). 24. Remove the plastic shipping caps and lubricate the new o-ring seals for front extension tubes with clean refrigerant oil. 25. Connect the underbody A/C line fittings to the front liquid and suction line extension tubes. Tighten the A/C line brass nuts to 17 ft. lbs. (23 N.m). 26. Connect the rubber hoses at the front of the underbody heater tube hoses to the rear heater extension tubes. 27. Using spring tension clamp pliers (Blue Point® YA9562 or equivalent), compress and slide the clamps that secure the heater hoses over the extension tubes. Release the clamp when it is correctly positioned over the tube. 28. Connect the rear underbody heater quick connect fittings to the rear heater core extension tubes. 29. Place the exhaust system into position and attach the exhaust hanger rubber isolators. 30. Lower the vehicle from the hoist. 31. Using an approved refrigerant evacuation machine, evacuate the A/C system. Follow the manufacturers instructions provided with the machine being used. 32. Refill the engine cooling system using the original coolant removed from the vehicle. 33. Using an approved refrigerant charging machine, charge the A/C system. Follow the manufacturers instructions provided with the machine being used. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1615 NOTE: Refer to the underhood A/C charge label for the correct amount of refrigerant to install into the A/C system (Figure 8). 34. Remove the A/C charging machine, close the hood and return the vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1616 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > Page 1617 Coolant Line/Hose: Specifications Water Pump Inlet Tube Bolts ............................................................................................................... ................................................. 28 Nm (250 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > Page 1618 Coolant Line/Hose: Service and Repair WATER PUMP INLET TUBE REMOVAL 1. Drain the cooling system. 2. Raise vehicle on hoist and remove the belt splash shield. Fig.34 3. Remove the radiator lower hose from inlet tube. Fig.35 4. Remove the oil cooler outlet/heater return hose from inlet tube (only if equipped with engine oil cooler). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Technical Service Bulletins > Page 1619 Fig.36 5. Remove the inlet tube bolts. 6. Remove the inlet tube. Discard the O-ring seal. INSTALLATION 1. Clean the inlet tube O-ring sealing surfaces on the timing cover housing and tube. 2. Apply Mopar Dielectric Grease or equivalent to the O-ring before installation. 3. Position new O-ring seal on inlet tube. 4. Install the inlet tube. Tighten bolts to 28 Nm (250 in. lbs.). 5. Connect radiator lower hose and heater return hose (if equipped with engine oil cooler) to the inlet tube. 6. Install the drive belt splash shield and lower vehicle. 7. Fill the cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Recalls for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement Technical Service Bulletin # F06 Date: 060401 Campaign - Underbody Heater Hose Replacement April 2006 Dealer Service Instructions for: Customer Satisfaction Notification F06 Underbody Heater Hoses Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 05-028 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2005 (RS) Dodge Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles equipped with rear Heater/Air Conditioning (sales code HBB) and Stow-n-Go seats (sales code CYC) or Stow-N-Go floor pan (sales code CYY or CYV). IMPORTANT: The above vehicles located in the "salt belt" are involved in Customer Satisfaction Notification F01 (Rear A/C Heater tube Corrosion) and therefore have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The underbody heater hoses on about 141,000 of the above vehicles may leak coolant at the heater tube crimps. This may result in the engine overheating. Engine damage can occur if an overheated engine continues to be driven. Repair The underbody heater hoses for the rear heater must be replaced. Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Recalls for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 1628 Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the hood. 2. Lower the spare tire using the crank handle inside the vehicle (approximately 10 turns). 3. Using pinch-off pliers, clamp off the heater hoses in the engine compartment that connect the rear heater tubes to the engine cooling system. 4. Lift the vehicle on an appropriate hoist. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Recalls for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 1629 5. Using a cut off wheel, grind a slot into the heater tube aluminum crimp band on the two rear heater hoses (Figure 1). CAUTION: Do not allow the grinding wheel to touch the aluminum heater tubes. 6. Remove the aluminum crimp band from the hose using expanding snap-ring pliers (Snap-on SRP5A or equivalent) (Figure 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Recalls for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 1630 7. Slide the spring clamps off of the heater core quick-connect fittings located on the rear heater core tubes (Figure 3). 8. Carefully remove both old heater hoses from the heater tubes. CAUTION: Residual coolant will come out of the hoses and tubes when the heater hoses are removed. Use an appropriate container to catch the coolant. 9. Remove and save the spring clamps on the old hoses. Then discard the old hoses. 10. Install two spring clamps onto each heater tube. 11. Using the short hoses supplied in the kit, install the new heater hoses onto the heater hose tubes and the heater core tube quick connects. 12. Place the spring clamps at each end of the new heater hose. NOTE: The wings of the spring clamps should be pointed downward. 13. Remove the spare tire heat shields to gain access to the front set of heater hoses. 14. Using a cut off wheel, grind a slot into the heater tube aluminum crimp band on the two heater hoses (Figure 4). CAUTION: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Recalls for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 1631 Do not allow the grinding wheel to touch the aluminum heater tubes. 15. Remove the aluminum crimp band from the hose using expanding snap-ring pliers (Snap-on SRP5A or equivalent) (Figure 2). 16. Slide the spring clamps off the heater hoses (Figure 3). 17. Remove the heater hoses from the vehicle. 18. Remove and save the spring clamps on the old hoses. Then discard the old hoses 19. Install two spring clamps onto each heater tube. 20. Using the long hoses supplied in the kit, install the new heater hoses onto the heater hose tubes. 21. Place the spring clamps at each end of the new heater hose. NOTE: The wings of the spring clamp should be pointed downward. 22. Install the tire heat shields. 23. Lower the vehicle. 24. Remove the pinch-off pliers on the heater hoses in the engine compartment. 25. Raise the spare tire into position using the crank handle inside the vehicle. 26. Check the engine coolant level and add coolant as required. 27. Start the engine and ensure that the new heater hoses do not leak. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Recalls for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 1632 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement Technical Service Bulletin # F06 Date: 060401 Campaign - Underbody Heater Hose Replacement April 2006 Dealer Service Instructions for: Customer Satisfaction Notification F06 Underbody Heater Hoses Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 05-028 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2005 (RS) Dodge Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles equipped with rear Heater/Air Conditioning (sales code HBB) and Stow-n-Go seats (sales code CYC) or Stow-N-Go floor pan (sales code CYY or CYV). IMPORTANT: The above vehicles located in the "salt belt" are involved in Customer Satisfaction Notification F01 (Rear A/C Heater tube Corrosion) and therefore have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The underbody heater hoses on about 141,000 of the above vehicles may leak coolant at the heater tube crimps. This may result in the engine overheating. Engine damage can occur if an overheated engine continues to be driven. Repair The underbody heater hoses for the rear heater must be replaced. Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 1638 Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the hood. 2. Lower the spare tire using the crank handle inside the vehicle (approximately 10 turns). 3. Using pinch-off pliers, clamp off the heater hoses in the engine compartment that connect the rear heater tubes to the engine cooling system. 4. Lift the vehicle on an appropriate hoist. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 1639 5. Using a cut off wheel, grind a slot into the heater tube aluminum crimp band on the two rear heater hoses (Figure 1). CAUTION: Do not allow the grinding wheel to touch the aluminum heater tubes. 6. Remove the aluminum crimp band from the hose using expanding snap-ring pliers (Snap-on SRP5A or equivalent) (Figure 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 1640 7. Slide the spring clamps off of the heater core quick-connect fittings located on the rear heater core tubes (Figure 3). 8. Carefully remove both old heater hoses from the heater tubes. CAUTION: Residual coolant will come out of the hoses and tubes when the heater hoses are removed. Use an appropriate container to catch the coolant. 9. Remove and save the spring clamps on the old hoses. Then discard the old hoses. 10. Install two spring clamps onto each heater tube. 11. Using the short hoses supplied in the kit, install the new heater hoses onto the heater hose tubes and the heater core tube quick connects. 12. Place the spring clamps at each end of the new heater hose. NOTE: The wings of the spring clamps should be pointed downward. 13. Remove the spare tire heat shields to gain access to the front set of heater hoses. 14. Using a cut off wheel, grind a slot into the heater tube aluminum crimp band on the two heater hoses (Figure 4). CAUTION: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 1641 Do not allow the grinding wheel to touch the aluminum heater tubes. 15. Remove the aluminum crimp band from the hose using expanding snap-ring pliers (Snap-on SRP5A or equivalent) (Figure 2). 16. Slide the spring clamps off the heater hoses (Figure 3). 17. Remove the heater hoses from the vehicle. 18. Remove and save the spring clamps on the old hoses. Then discard the old hoses 19. Install two spring clamps onto each heater tube. 20. Using the long hoses supplied in the kit, install the new heater hoses onto the heater hose tubes. 21. Place the spring clamps at each end of the new heater hose. NOTE: The wings of the spring clamp should be pointed downward. 22. Install the tire heat shields. 23. Lower the vehicle. 24. Remove the pinch-off pliers on the heater hoses in the engine compartment. 25. Raise the spare tire into position using the crank handle inside the vehicle. 26. Check the engine coolant level and add coolant as required. 27. Start the engine and ensure that the new heater hoses do not leak. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 1642 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front Heater Hose: Service and Repair Front Heater Inlet Hose REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The heater inlet hose is constructed from formed steel tubing and rubber hoses. Depending on application, the ends are secured to the heater core, engine oil cooler or the engine by spring tension clamps. 1. Drain the engine cooling system. Heater Inlet Hose - 2.4L Shown, 2.5L Typical Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front > Page 1645 Heater Inlet Hose - 3.3L/3.8L W/O Rear Heater Heater Inlet Hose - 3.3L/3.8L With Rear Heater 2. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes/heater core, causing an engine coolant leak. 3. Disconnect each hose end by carefully twisting the hose back and forth on the tube or nipple, while gently pulling it away from the end of the tube or nipple. NOTE: Replacement of the heater inlet hoses will be required if the hose ends are cut for removal. 4. If necessary, carefully cut the hose end and peel the hose off of the tube or nipple. INSTALLATION 1. Using spring tension clamp pliers, compress and slide each clamp away from the end of the hose being installed. 2. Install each hose by carefully twisting the hose back and forth while gently pushing it onto the tube or nipple end. 3. Using spring tension clamp pliers, compress and slide the clamps onto each end of the hose being installed. 4. Refill the engine cooling system. Heater Return Hose REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The heater return tube is constructed from formed steel tubing and rubber hoses. Depending on application, the ends are secured to the heater core, engine oil cooler or the engine by spring tension clamps. 1. Drain the engine cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front > Page 1646 Heater Return Hose - 2.4L Shown, 2.5L Typical Heater Return Hose - 3.3L/3.8L W/O Rear Heater Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front > Page 1647 Heater Hoses - 3.3/3.8L With Rear Heater 2. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes/heater core, causing an engine coolant leak. 3. Disconnect each hose end by carefully twisting the hose back and forth on the tube or nipple, while gently pulling it away from the end of the tube or nipple. NOTE: Replacement of the heater return hoses will be required if the hose ends are cut for removal. 4. If necessary, carefully cut the hose end and peel the hose off of the tube or nipple. INSTALLATION 1. Using spring tension clamp pliers, compress and slide the clamp away from the end of the heater return hose. 2. Install each hose end by carefully twisting the hose back and forth while gently pushing it onto the tube. 3. Using spring tension clamp pliers, compress and slide the clamps onto each end of the heater return hose. 4. Refill the engine cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Front > Page 1648 Heater Hose: Service and Repair Rear Heater Hoses REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Drain the engine cooling system. 2. Raise and support the vehicle. 3. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes, causing an engine coolant leak. Underbody Heater Hose Connections - Front 4. Disconnect the front underbody heater inlet and return hose by carefully twisting the hoses back and forth on the underbody tubes, while gently pulling them away from the end of the tubes. 5. If necessary, carefully cut the hose ends and peel the hoses off of the tubes. NOTE: Replacement of the heater hoses will be required if the hose ends are cut for removal. INSTALLATION 1. Install the front underbody heater inlet and return hoses by carefully twisting the hoses back and forth on the underbody tubes, while gently pushing them onto the end of the tubes. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes, causing an engine coolant leak. 2. Using spring tension clamp pliers, compress and slide the clamps that secure each end of the heater hose over the tubes. Release the clamp when it is over the tube. 3. Lower the vehicle. 4. Refill the engine cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Recalls for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion Technical Service Bulletin # F01 Date: 060201 Campaign - Rear A/C/Heater Tube Corrosion February 2006 Dealer Service Instructions for: Customer Satisfaction Notification F01 Rear A/C and Heater Tube Corrosion Effective immediately all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 05-028 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2005 (RS) Dodge Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles equipped with rear Heater/Air Conditioning (sales code HBB) and Stow-n-Go seats (sales code CYC) or Stow-N-Go floor pan (sales code CYY or CYV). IMPORTANT: Only the above vehicles sold or currently registered in "salt belt" states (where large amounts of road salt are used for snow and ice removal) are involved. See "Owner Notification and Service Scheduling" section for a list of salt belt states. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The underbody rear A/C and heater tube mounting brackets on about 239,800 of the above vehicles may have insufficient corrosion protection. Excessive corrosion can cause the rear A/C or heater tubes to leak. This may result in either an inoperative A/C system or engine overheating. Engine damage can occur if an overheated engine continues to be driven. Repair The underbody rear A/C and heater tube assembly must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Recalls for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1657 Parts Information Completion Reporting and Reimbursement DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Only vehicles sold or currently registered in "Salt Belt" states (where large amounts of road salt are used for snow and ice removal) are involved. The Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Recalls for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1658 following states are "Salt Belt" states: Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the hood. 2. Using an approved refrigerant recovery machine, recover the refrigerant from the air conditioning system. Follow the manufacturers instructions provided with the machine being used. 3. Using a suitable clean container, drain the coolant from the engine cooling system. Save the coolant for reuse. 4. Raise the vehicle on an appropriate hoist. 5. Disconnect the exhaust system from the exhaust hanger rubber isolators and position the exhaust system out of the way. 6. Disconnect the underbody A/C lines from the front liquid and suction line extension tubes (Figure 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Recalls for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1659 7. Remove the nut that secures the underbody A/C lines to the rear evaporator tapping plate (Figure 2). 8. Disconnect the underbody A/C lines from the evaporator tapping plate. NOTE: The A/C line mounting block may not come loose after removing the retaining nut due to corrosion between the mounting block and the retaining stud. Do not use excessive force to attempt to remove the mounting block from the evaporator. Evaporator damage may occur. Using an air chisel with a flat nose bit, gently pull down on the A/C lines and then lightly rap on the end of the stud with the bit of the air chisel (Figure 3). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Recalls for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1660 9. Remove the fasteners that secure the four underbody line retaining straps to the vehicles underbody (Figure 4). 10. Remove the fastener that secures the right rear brake line bracket to the underbody (Figure 5). 11. Disconnect the underbody heater tubes at the rear of the vehicle by releasing the insert in the underbody heater tube quick connect fittings and Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Recalls for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1661 carefully pull downward on the heater tube fitting. CAUTION: Residual coolant will come out of the heater hoses when they are removed. Be prepared to catch the residual coolant in a suitable container. 12. Lower the underbody heater tubes to drain any residual coolant from the tubes. 13. Using spring tension clamp pliers (Blue Point(R) YA9562 or equivalent), compress and slide the clamps off the rubber hoses at the front of the underbody coolant tubes. 14. Disconnect the heater hoses by carefully twisting the hoses back and forth while gently pulling them away from the end of the coolant tubes. 15. Remove and discard the underbody rear A/C and heater tubes. 16. Using locking pliers, remove and discard the stud from the evaporator tapping plate. CAUTION: Failure to replace the stud will cause future A/C tube failure. The new stud has an additional coating to prevent corrosion. 17. Using an E7 Torx(R) socket (Snap-on(R) TLE70A or equivalent), install the new stud provided in the kit into the evaporator tapping plate (Figure 6). Tighten the stud to 80 in. lbs. (9 N.m). 18. Remove the plastic shipping cap on the A/C mounting block and pour 1 oz. of PAG oil (P/N 82300102) into the A/C suction line. Then temporarily reinstall the shipping cap. 19. Position the new line kit under the vehicle and install the fasteners that secure the four retaining straps to the vehicle. Tighten the fasteners to 65 in. lbs. (7 N.m). 20. Position the rear brake line bracket and install the fastener. Tighten the fastener to 250 in. lbs. (28 N.m). 21. Remove and discard the plastic shipping cap from the A/C mounting block and lubricate the new o-ring seals with clean refrigerant oil. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Recalls for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1662 22 Connect the underbody A/C lines to the rear evaporator tapping plate (Figure 7). 23. Install the new nut/washer, provided in the kit, to secure the underbody A/C line mounting block to the rear evaporator tapping plate (Figure 7). Tighten the nut to 17 ft. lbs. (23 N.m). 24. Remove the plastic shipping caps and lubricate the new o-ring seals for front extension tubes with clean refrigerant oil. 25. Connect the underbody A/C line fittings to the front liquid and suction line extension tubes. Tighten the A/C line brass nuts to 17 ft. lbs. (23 N.m). 26. Connect the rubber hoses at the front of the underbody heater tube hoses to the rear heater extension tubes. 27. Using spring tension clamp pliers (Blue Point® YA9562 or equivalent), compress and slide the clamps that secure the heater hoses over the extension tubes. Release the clamp when it is correctly positioned over the tube. 28. Connect the rear underbody heater quick connect fittings to the rear heater core extension tubes. 29. Place the exhaust system into position and attach the exhaust hanger rubber isolators. 30. Lower the vehicle from the hoist. 31. Using an approved refrigerant evacuation machine, evacuate the A/C system. Follow the manufacturers instructions provided with the machine being used. 32. Refill the engine cooling system using the original coolant removed from the vehicle. 33. Using an approved refrigerant charging machine, charge the A/C system. Follow the manufacturers instructions provided with the machine being used. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Recalls for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1663 NOTE: Refer to the underhood A/C charge label for the correct amount of refrigerant to install into the A/C system (Figure 8). 34. Remove the A/C charging machine, close the hood and return the vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Recalls for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1664 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion Technical Service Bulletin # F01 Date: 060201 Campaign - Rear A/C/Heater Tube Corrosion February 2006 Dealer Service Instructions for: Customer Satisfaction Notification F01 Rear A/C and Heater Tube Corrosion Effective immediately all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 05-028 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2005 (RS) Dodge Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles equipped with rear Heater/Air Conditioning (sales code HBB) and Stow-n-Go seats (sales code CYC) or Stow-N-Go floor pan (sales code CYY or CYV). IMPORTANT: Only the above vehicles sold or currently registered in "salt belt" states (where large amounts of road salt are used for snow and ice removal) are involved. See "Owner Notification and Service Scheduling" section for a list of salt belt states. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The underbody rear A/C and heater tube mounting brackets on about 239,800 of the above vehicles may have insufficient corrosion protection. Excessive corrosion can cause the rear A/C or heater tubes to leak. This may result in either an inoperative A/C system or engine overheating. Engine damage can occur if an overheated engine continues to be driven. Repair The underbody rear A/C and heater tube assembly must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1670 Parts Information Completion Reporting and Reimbursement DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Only vehicles sold or currently registered in "Salt Belt" states (where large amounts of road salt are used for snow and ice removal) are involved. The Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1671 following states are "Salt Belt" states: Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the hood. 2. Using an approved refrigerant recovery machine, recover the refrigerant from the air conditioning system. Follow the manufacturers instructions provided with the machine being used. 3. Using a suitable clean container, drain the coolant from the engine cooling system. Save the coolant for reuse. 4. Raise the vehicle on an appropriate hoist. 5. Disconnect the exhaust system from the exhaust hanger rubber isolators and position the exhaust system out of the way. 6. Disconnect the underbody A/C lines from the front liquid and suction line extension tubes (Figure 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1672 7. Remove the nut that secures the underbody A/C lines to the rear evaporator tapping plate (Figure 2). 8. Disconnect the underbody A/C lines from the evaporator tapping plate. NOTE: The A/C line mounting block may not come loose after removing the retaining nut due to corrosion between the mounting block and the retaining stud. Do not use excessive force to attempt to remove the mounting block from the evaporator. Evaporator damage may occur. Using an air chisel with a flat nose bit, gently pull down on the A/C lines and then lightly rap on the end of the stud with the bit of the air chisel (Figure 3). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1673 9. Remove the fasteners that secure the four underbody line retaining straps to the vehicles underbody (Figure 4). 10. Remove the fastener that secures the right rear brake line bracket to the underbody (Figure 5). 11. Disconnect the underbody heater tubes at the rear of the vehicle by releasing the insert in the underbody heater tube quick connect fittings and Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1674 carefully pull downward on the heater tube fitting. CAUTION: Residual coolant will come out of the heater hoses when they are removed. Be prepared to catch the residual coolant in a suitable container. 12. Lower the underbody heater tubes to drain any residual coolant from the tubes. 13. Using spring tension clamp pliers (Blue Point(R) YA9562 or equivalent), compress and slide the clamps off the rubber hoses at the front of the underbody coolant tubes. 14. Disconnect the heater hoses by carefully twisting the hoses back and forth while gently pulling them away from the end of the coolant tubes. 15. Remove and discard the underbody rear A/C and heater tubes. 16. Using locking pliers, remove and discard the stud from the evaporator tapping plate. CAUTION: Failure to replace the stud will cause future A/C tube failure. The new stud has an additional coating to prevent corrosion. 17. Using an E7 Torx(R) socket (Snap-on(R) TLE70A or equivalent), install the new stud provided in the kit into the evaporator tapping plate (Figure 6). Tighten the stud to 80 in. lbs. (9 N.m). 18. Remove the plastic shipping cap on the A/C mounting block and pour 1 oz. of PAG oil (P/N 82300102) into the A/C suction line. Then temporarily reinstall the shipping cap. 19. Position the new line kit under the vehicle and install the fasteners that secure the four retaining straps to the vehicle. Tighten the fasteners to 65 in. lbs. (7 N.m). 20. Position the rear brake line bracket and install the fastener. Tighten the fastener to 250 in. lbs. (28 N.m). 21. Remove and discard the plastic shipping cap from the A/C mounting block and lubricate the new o-ring seals with clean refrigerant oil. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1675 22 Connect the underbody A/C lines to the rear evaporator tapping plate (Figure 7). 23. Install the new nut/washer, provided in the kit, to secure the underbody A/C line mounting block to the rear evaporator tapping plate (Figure 7). Tighten the nut to 17 ft. lbs. (23 N.m). 24. Remove the plastic shipping caps and lubricate the new o-ring seals for front extension tubes with clean refrigerant oil. 25. Connect the underbody A/C line fittings to the front liquid and suction line extension tubes. Tighten the A/C line brass nuts to 17 ft. lbs. (23 N.m). 26. Connect the rubber hoses at the front of the underbody heater tube hoses to the rear heater extension tubes. 27. Using spring tension clamp pliers (Blue Point® YA9562 or equivalent), compress and slide the clamps that secure the heater hoses over the extension tubes. Release the clamp when it is correctly positioned over the tube. 28. Connect the rear underbody heater quick connect fittings to the rear heater core extension tubes. 29. Place the exhaust system into position and attach the exhaust hanger rubber isolators. 30. Lower the vehicle from the hoist. 31. Using an approved refrigerant evacuation machine, evacuate the A/C system. Follow the manufacturers instructions provided with the machine being used. 32. Refill the engine cooling system using the original coolant removed from the vehicle. 33. Using an approved refrigerant charging machine, charge the A/C system. Follow the manufacturers instructions provided with the machine being used. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1676 NOTE: Refer to the underhood A/C charge label for the correct amount of refrigerant to install into the A/C system (Figure 8). 34. Remove the A/C charging machine, close the hood and return the vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 1677 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 1678 Hose/Line HVAC: Service Precautions WARNING: - THE A/C SYSTEM CONTAINS REFRIGERANT UNDER HIGH PRESSURE. REPAIRS SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL. SEVERE PERSONAL INJURY OR DEATH MAY RESULT FROM IMPROPER SERVICE PROCEDURES. - AVOID BREATHING THE REFRIGERANT AND REFRIGERANT OIL VAPOR OR MIST. EXPOSURE MAY IRRITATE THE EYES, NOSE, AND/OR THROAT. WEAR EYE PROTECTION WHEN SERVICING THE A/C REFRIGERANT SYSTEM. SERIOUS EYE INJURY CAN RESULT FROM DIRECT CONTACT WITH THE REFRIGERANT. IF EYE CONTACT OCCURS, SEEK MEDICAL ATTENTION IMMEDIATELY. - DO NOT EXPOSE THE REFRIGERANT TO OPEN FLAME. POISONOUS GAS IS CREATED WHEN REFRIGERANT IS BURNED. AN ELECTRONIC LEAK DETECTOR IS RECOMMENDED. SEVERE PERSONAL INJURY OR DEATH MAY RESULT FROM IMPROPER SERVICE PROCEDURES. - IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE THE WORK AREA BEFORE RESUMING SERVICE. LARGE AMOUNTS OF REFRIGERANT RELEASED IN A CLOSED WORK AREA WILL DISPLACE THE OXYGEN AND CAUSE SUFFOCATION AND DEATH. - THE EVAPORATION RATE OF R-134A REFRIGERANT AT AVERAGE TEMPERATURE AND ALTITUDE IS EXTREMELY HIGH. AS A RESULT, ANYTHING THAT COMES IN CONTACT WITH THE REFRIGERANT WILL FREEZE. ALWAYS PROTECT THE SKIN OR DELICATE OBJECTS FROM DIRECT CONTACT WITH THE REFRIGERANT. - THE R-134A SERVICE EQUIPMENT OR THE VEHICLE REFRIGERANT SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR AND R-134A HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS, AND MAY RESULT IN FIRE OR EXPLOSION CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. - THE ENGINE COOLING SYSTEM IS DESIGNED TO DEVELOP INTERNAL PRESSURES OF 97 TO 123 KILOPASCALS (14 TO 18 POUNDS PER SQUARE INCH). DO NOT REMOVE OR LOOSEN THE COOLANT PRESSURE CAP, CYLINDER BLOCK DRAIN PLUGS, RADIATOR DRAIN, RADIATOR HOSES, HEATER HOSES, OR HOSE CLAMPS WHILE THE ENGINE COOLING SYSTEM IS HOT AND UNDER PRESSURE. ALLOW THE VEHICLE TO COOL FOR A MINIMUM OF 15 MINUTES BEFORE OPENING THE COOLING SYSTEM FOR SERVICE. FAILURE TO OBSERVE THIS WARNING CAN RESULT IN SERIOUS BURNS FROM THE HEATED ENGINE COOLANT. CAUTION: - Never add R-12 to a refrigerant system designed to use R-134a. Do not use R-12 equipment or parts on a R-134a A/C system. These refrigerants are not compatible and damage to the A/C system will result. - Never use R-12 refrigerant oil in a A/C system designed to use R-134a refrigerant oil. These refrigerant oils are not compatible and damage to the A/C system will result. - The use of A/C system sealers may result in damage to A/C refrigerant recovery/evacuation/recharging equipment and/or A/C system. Many federal, state/provincial and local regulations prohibit the recharge of A/C systems with known leaks. DaimlerChrysler recommends the detection of A/C system leaks through the use of approved leak detectors and fluorescent leak detection dyes. Vehicles found with A/C system sealers should be treated as contaminated and replacement of the entire A/C refrigerant system is recommended. A/C systems found to be contaminated with A/C system sealers, A/C stop-leak products or seal conditioners voids the warranty for the A/C system. - Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. - If equipped, do not remove the secondary retention clip from any spring-lock coupler connection while the refrigerant system is under pressure. Recover the refrigerant before removing the secondary retention clip. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. - The internal parts of the A/C system will remain stable as long as moisture-free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. Keep service tools and the work area clean. Do not open the refrigerant system or uncap a replacement component until you are ready to service the system. Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug. This will prevent contamination from entering the A/C system. - Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a container of refrigerant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container. - Do not overcharge the refrigerant system. Overcharging will cause excessive compressor head pressure and can cause compressor noise and A/C system failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Plumbing Hose/Line HVAC: Description and Operation Plumbing The A/C refrigerant lines and hoses are used to carry the refrigerant between the various A/C system components. The refrigerant lines and hoses for the R-134a system on this vehicle consist of a barrier-hose design with a nylon tube sandwiched between rubber layers. The nylon tube helps to contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant lines are made from lightweight aluminum or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant lines and hoses will reduce the capacity of the entire A/C system and can reduce the flow of refrigerant in the system. The radius of all bends in the flexible hose refrigerant lines should be at least ten times the diameter of the hose and the refrigerant lines should be routed so they are at least 80 millimeters (3 inches) away from the exhaust manifold(s) and exhaust pipe(s). High pressures are produced in the refrigerant system when the A/C compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. The refrigerant lines and hoses are coupled to other A/C system components with block-type fittings. An O-ring seal, or a flat steel gasket with an integral O-ring (dual plane seal), is used to mate the refrigerant line fittings with A/C system components to ensure the integrity of the refrigerant system. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Plumbing > Page 1681 Hose/Line HVAC: Description and Operation Underbody Lines Rear Heater And A/C Lines - Typical Underbody lines are used on models equipped with the rear heating-A/C system. The underbody suction line, liquid line, and heater tubes can each be serviced separately. Rear Heater And A/C Lines - Typical Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Plumbing > Page 1682 Front Extension Lines To Underbody Lines - Typical The rear heating-A/C underbody lines are all serviced as individual components. When disconnecting any line or connection, make sure that the area around the line or connection is clean of any dirt or residue that may enter and contaminate the rear heating-A/C system. WARNING: HIGH PRESSURES ARE PRODUCED IN THE REFRIGERANT SYSTEM WHEN THE A/C COMPRESSOR IS OPERATING. HIGH TEMPERATURE COOLANT IS PRESENT IN THE HEATER PLUMBING WHEN THE ENGINE IS OPERATING. EXTREME CARE MUST BE EXERCISED WHEN SERVICING THE REAR HEATER AND A/C LINES TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH. Any kinks or sharp bends in the rear heater-A/C plumbing will reduce the capacity of the entire heating-A/C system. Kinks and sharp bends reduce the system flow. High pressures are produced in the refrigerant system when the A/C compressor is operating. High temperature coolant is present in the heater plumbing when the engine is operating. Extreme care must be exercised to make sure that each of the connections is pressure-tight and leak free. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > Page 1683 Hose/Line HVAC: Testing and Inspection REFRIGERANT SYSTEM LEAKS WARNING: R-134A SERVICE EQUIPMENT OR VEHICLE A/C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. MIXTURE OF AIR AND R-134A CAN BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. AVOID BREATHING A/C REFRIGERANT AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY IRRITATE EYES, NOSE AND THROAT. USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO DISCHARGE R-134A SYSTEM. IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE WORK AREA BEFORE RESUMING SERVICE. If the A/C system is not cooling properly, determine if the refrigerant system is fully charged with R-134a. If while performing this test A/C liquid line pressure is less than 345 kPa (50 psi) proceed to System Empty procedure. If liquid line pressure is greater than 345 kPa (50 psi) proceed to System Low procedure. If the refrigerant system is empty or low in refrigerant charge, a leak at any line fitting or component seal is likely. A review of the fittings, lines and components for oily residue is an indication of the leak location. To detect a leak in the refrigerant system, perform one of the following procedures as indicated by the results of the refrigerant system charge level test. SYSTEM EMPTY 1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approx. 28 in Hg.). Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed with this procedure. 2. Prepare a 0.284 Kg. (10 oz.) refrigerant charge to be injected into the system. 3. Connect and dispense 0.284 Kg. (10 oz.) of refrigerant into the evacuated refrigerant system. 4. Proceed to the SYSTEM LOW procedures. SYSTEM LOW 1. Position the vehicle in a wind-free work area. This will aid in detecting small leaks. 2. Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run for five minutes with the system set to the following: Transaxle in Park - Engine idling - Rear A/C Off (if equipped) - A/C controls set to 100 percent outside air - Blower switch in the highest speed position - A/C in the On position - Front windows open CAUTION: A leak detector designed for R-12 refrigerant (only) will not detect leaks in a R-134a refrigerant system. 3. Shut off the vehicle and wait 2 to 7 minutes. Then use an electronic leak detector that is designed to detect R-134a type refrigerant and search for leaks. Fittings, lines, or components that appear to be oily usually indicates a refrigerant leak. To inspect the evaporator core for leaks, insert the leak detector probe into the drain tube opening or a heat duct. A R-134a dye is available to aid in leak detection, use only DaimlerChrysler approved refrigerant dye. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line Hose/Line HVAC: Service and Repair A/C Discharge Line REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Remove the right headlamp unit. A/C Discharge Line To A/C Condenser - Typical 3. Remove the nut that secures the A/C discharge line to the right end of the A/C condenser. 4. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket. 5. Install plugs in, or tape over the opened discharge line fitting and the condenser inlet port. 6. Raise and support the vehicle. 7. On models equipped with the 2.5L and 2.8L diesel engines, remove the belly pan from underneath the engine compartment. A/C Discharge Line To Compressor - Typical Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1686 8. Remove the nut that secures the A/C discharge line to the A/C compressor. 9. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring seal and gasket. 10. Install plugs in, or tape over the opened discharge line fitting and the compressor discharge port. 11. Remove the A/C discharge line from the engine compartment. INSTALLATION 1. Position the A/C discharge line into the engine compartment. 2. Remove the tape or plugs from the compressor discharge port and the discharge line fitting. 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. 4. Install the A/C discharge line to the A/C compressor. 5. Install the nut that secures the A/C discharge line to the A/C compressor. Tighten the nut to 23 N.m (17 ft. lbs.). 6. On models with the 2.5L and 2.8L diesel engine, install the belly pan. 7. Lower the vehicle. 8. Remove the tape or plugs from the condenser inlet port and the discharge line fitting. 9. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. 10. Install the A/C discharge line to the A/C condenser. 11. Install the nut that secures the A/C discharge line to the A/C condenser. Tighten the nut to 23 N.m (17 ft. lbs.). 12. Install the right headlamp unit. 13. Evacuate the refrigerant system. 14. Charge the refrigerant system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1687 Hose/Line HVAC: Service and Repair Liquid Line Front Section WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The front A/C liquid line is serviced in two sections. The front connects between the A/C condenser and the receiver/drier and includes the high side service port. The rear connects between the receiver/drier and the A/C expansion valve and includes the fitting for the A/C pressure transducer. On models equipped with the rear heating-A/C system, the rear of the front A/C liquid line also includes a hose and tube extension that connects the front liquid line to the liquid line for the rear A/C system. REMOVAL 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Remove the right headlamp unit. A/C Condenser - Typical 4. Remove the nut that secures the A/C liquid line to the right end of the A/C condenser. 5. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket. 6. Install plugs in, or tape over the opened liquid line fitting and the condenser outlet port. 7. Remove the air cleaner housing and the air inlet tube. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1688 A/C Liquid Line - LHD Shown, RHD Typical 8. Disengage the retainer that secures the liquid line routing clip to the top of the right frame rail ahead of the front strut tower in the engine compartment. 9. Remove the bolt that secures the front of the A/C liquid line to the receiver/drier. 10. Disconnect the A/C liquid line from the receiver/drier and remove and discard the O-ring seal. 11. Install plugs in, or tape over the opened liquid line fitting and the receiver/drier inlet port. INSTALLATION 1. Position the front of the A/C liquid line into the engine compartment. 2. Remove the tape or plugs from the liquid line fitting and the receiver/drier inlet port. 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it onto the liquid line fitting. 4. Connect the A/C liquid line to the receiver/ drier. 5. Install the bolt that secures the A/C liquid line to the receiver/drier. Tighten the bolt to 11 N.m (97 in. lbs.). 6. Engage the retainer that secures the liquid line routing clip to the top of the right frame rail ahead of the front strut tower in the engine compartment. 7. Install the air cleaner housing and air inlet tube. 8. Remove the tape or plugs from the condenser outlet port and the liquid line fitting. 9. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. 10. Connect the A/C liquid line to the A/C condenser. 11. Install the nut that secures the A/C liquid line to the A/C condenser. Tighten the nut to 23 N.m (17 ft. lbs.). 12. Install the right headlamp unit. 13. Reconnect the negative battery cable. 14. Evacuate the refrigerant system. 15. Charge the refrigerant system. Rear Section WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The front A/C liquid line is serviced in two sections. The front connects between the A/C condenser and the receiver/drier and includes the high Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1689 side service port. The rear connects between the receiver/drier and the A/C expansion valve and includes the fitting for the A/C pressure transducer. On models equipped with the rear heating-A/C system, the rear of the front A/C liquid line also includes a hose and tube extension that connects the front liquid line to the liquid line for the rear A/C system. REMOVAL 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Remove the air cleaner housing and the air inlet tube. 4. Disconnect the drain tube from the wiper module drain on the right side of the engine compartment. 5. Remove the A/C pressure transducer. A/C Liquid Line - LHD Shown, RHD Typical 6. If equipped, remove the nut that secures the A/C ground strap to the weld stud on the top of the right front strut tower. 7. If equipped, remove the A/C ground strap eyelet terminal connector from the weld stud. 8. Remove the bolt that secures the rear of the A/C liquid line to the receiver/drier. 9. Disconnect the A/C liquid line from the receiver/drier and remove and discard the O-ring seal. 10. Install plugs in, or tape over the opened liquid line fitting and the receiver/drier outlet port. 11. Remove the nut that secures the A/C suction line and the A/C liquid line to the A/C expansion valve. 12. Disconnect the A/C suction line and the A/C liquid line from the A/C expansion valve and remove and discard the O-ring seals. 13. Install plugs in, or tape over the opened suction line and liquid line fittings and both expansion valve ports. 14. On RHD models, remove the rear of the A/C liquid line from the retaining bracket located at the top of the dash panel 15. If the vehicle is equipped with the optional rear heating-A/C system, go to Step 16. If the vehicle is not equipped with the optional rear heating-A/C system, go to Step 22. 16. Raise and support the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1690 Underbody A/C Line Connections 17. Cut the tie strap located just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heating-A/C system. 18. Disconnect the A/C liquid line extension fitting from the underbody liquid line fitting for the rear A/C system. 19. Remove the O-ring seal from the underbody liquid line fitting and discard. 20. Install plugs in, or tape over the opened liquid line fittings. 21. Lower the vehicle. 22. Remove the rear of the A/C liquid line from the engine compartment. INSTALLATION 1. Position the rear of the A/C liquid line into the engine compartment. 2. Remove the tape or plugs from the suction line and liquid line fittings and both expansion valve ports. 3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the suction line and liquid line fittings. 4. Reconnect the A/C liquid line and the A/C suction line to the A/C expansion valve. 5. Install the nut that secures the rear of the A/C liquid line and the A/C suction line to the A/C expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.). 6. Remove the tape or plugs from the liquid line fitting and the receiver/drier outlet port. 7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting. 8. Reconnect the A/C liquid line to the receiver/ drier. 9. Install the bolt that secures the A/C liquid line to the receiver/drier. Tighten the bolt to 11 N.m (97 in. lbs.). 10. If equipped, reinstall the A/C ground strap eyelet terminal connector onto the weld stud on the top of the right front strut tower (if equipped). 11. If equipped, install the nut that secures the A/C ground strap to the weld stud. Tighten the nut to 12 N.m (106 in. lbs.). 12. Install the A/C pressure transducer. 13. Connect the drain tube to the wiper module drain on the right side of the engine compartment. 14. Install the air cleaner housing and air inlet tube. 15. On RHD models, install the liquid line into the retaining bracket located at the top of the dash panel. 16. If the vehicle is equipped with the optional rear heating-A/C system, go to Step 17. If the vehicle does not have the optional rear heating-A/C system, go to Step 23. 17. Raise and support the vehicle. 18. Remove the tape or plugs from the A/C liquid line extension fitting and the underbody liquid line fitting. 19. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the underbody liquid line fitting. 20. Connect the A/C liquid line extension fitting to the underbody liquid line fitting. Tighten the fittings to 23 N.m (17 ft. lbs.). 21. Install a new tie strap just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heating-A/C system. 22. Lower the vehicle. 23. Reconnect the negative battery cable. 24. Evacuate the refrigerant system. 25. Charge the refrigerant system. Rear REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1691 FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: On models equipped with the rear A/C system, the rear of the front A/C liquid line also includes a hose and tube extension that connects the front liquid line to the underbody liquid line. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Remove the air cleaner housing from the right side of the engine compartment. 4. Disconnect the drain tube from the wiper module drain on the right side of the engine compartment. 5. Remove the A/C pressure transducer. Liquid Line 6. If equipped, remove the nut that secures the A/C ground strap to the weld stud on the top of the right front strut tower. 7. If equipped, remove the A/C ground strap eyelet terminal connector from the weld stud. 8. Remove the bolt that secures the rear of the front liquid line to the top of the receiver/drier. 9. Disconnect the rear of the front liquid line from the top of the receiver/drier and remove and discard the O-ring seal. 10. Install plugs in, or tape over the opened liquid line fitting and the receiver/drier port. 11. Remove the nut that secures the suction and liquid line to the A/C expansion valve. 12. Disconnect the suction line and liquid lines from the A/C expansion valve and remove and discard the seals. 13. Install plugs in, or tape over the opened suction and liquid line fittings and expansion valve ports. 14. Raise and support the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1692 Underbody A/C Line Front Connections - Typical 15. Remove the tie strap and disconnect the front liquid line from the underbody liquid line and remove and discard the O-ring seal. 16. Install plugs in, or tape over the opened liquid line fittings. 17. Lower the vehicle. 18. Remove the liquid line from the engine compartment. INSTALLATION 1. Position the rear of the front liquid line into the engine compartment. 2. Remove the tape or plugs from the suction and liquid line fittings and expansion valve ports. 3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the suction and liquid line fittings. 4. Connect the suction and liquid lines to the A/C expansion valve. 5. Install the nut that secures the suction and liquid lines to the A/C expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.). 6. Remove the tape or plugs from the liquid line fitting for the receiver/drier and the receiver/drier port. 7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting. 8. Reconnect the liquid line to the receiver/drier. 9. Install the bolt that secures the liquid line to the receiver/drier. Tighten the bolt to 11 N.m (97 in. lbs.). 10. If equipped, reinstall the A/C ground strap eyelet terminal connector onto the weld stud on the top of the right front strut tower (if equipped). 11. If equipped, install the nut that secures the A/C ground strap to the weld stud. Tighten the nut to 12 N.m (106 in. lbs.). 12. Install the A/C pressure transducer. 13. Connect the drain tube to the wiper module drain on the right side of the engine compartment. 14. Install the air cleaner housing into the right side of the engine compartment. 15. Raise and support the vehicle. 16. Remove the tape or plugs from the liquid line rear extension fitting and the underbody liquid line. 17. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the underbody liquid line. 18. Connect the liquid line rear extension fitting to the underbody liquid line. Tighten the fittings to 23 N.m (17 ft. lbs.). 19. Install a new tie strap just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heating-A/C system. 20. Lower the vehicle. 21. Reconnect the negative battery cable. 22. Evacuate the refrigerant system. 23. Charge the refrigerant system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1693 Hose/Line HVAC: Service and Repair Suction Line Front REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The front suction line includes the low side service port near the A/C compressor. On models equipped with the rear A/C system, the front suction line also includes a suction line hose and tube extension that connects the front suction line to the suction line for the rear A/C system. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Remove the air cleaner top cover and snorkel from the air cleaner housing located on the right side of the engine compartment. 4. Disconnect the drain tube from the wiper module drain on the right side of the engine compartment. 5. Remove the nut that secures the suction line fitting to the top of the A/C compressor. 6. Disconnect the suction line fitting from the compressor suction port and remove and discard the O-ring seal. 7. Install plugs in, or tape over the opened suction line fitting and the compressor suction port. Suction Line - LHD Shown, RHD Typical 8. Remove the retainer that secures the suction line routing clip to the receiver/drier mounting bracket on the side of the right front strut tower in the engine compartment. 9. Remove the nut that secures the suction line and liquid line fittings to the A/C expansion valve. 10. Disconnect the suction line and liquid line fittings from the expansion valve and remove and discard the seals. 11. Install plugs in, or tape over the opened suction line and liquid line fittings and both expansion valve ports. 12. Remove the suction line from the retaining bracket located at the top of the dash panel. 13. If the vehicle is equipped with the rear heating-A/C system, go to Step 14. If the vehicle does not have the rear heating-A/C system, go to Step 19. 14. Raise and support the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1694 Underbody A/C Line Connections 15. Cut the tie strap located just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heating-A/C system. 16. Disconnect the suction line extension fitting from the underbody suction line fitting for the rear A/C system and remove and discard the O-ring seal. 17. Install plugs in, or tape over the opened suction line fittings. 18. Lower the vehicle. 19. Remove the suction line from the engine compartment. INSTALLATION 1. Position the suction line into the engine compartment. 2. Remove the tape or plugs from the suction line and liquid line fittings and both expansion valve ports. 3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the suction line and liquid line fittings. 4. Reconnect the liquid line and suction line fittings to the expansion valve. 5. Install the nut that secures the suction line and liquid line fittings to the expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.). 6. Install the retainer that secures the suction line routing clip to the receiver/drier mounting bracket on the side of the right front strut tower in the engine compartment. 7. Remove the tape or plugs from the compressor suction port and the suction line fitting. 8. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the suction line fitting. 9. Install a new dual plan seal and reconnect the suction line fitting to the compressor suction port. 10. Install the nut that secures the suction line fitting to the A/C compressor. Tighten the nut to 23 N.m (17 ft. lbs.). 11. Reconnect the drain tube to the wiper module drain on the right side of the engine compartment. 12. Install the air cleaner top cover and snorkel onto the air cleaner housing located on the right side of the engine compartment. 13. On RHD models, install the suction line into the retaining bracket located at the top of the dash panel. 14. If the vehicle is equipped with the rear heating-A/C system, go to Step 15. If the vehicle does not have the rear heating-A/C system, go to Step 21. 15. Raise and support the vehicle. 16. Remove the tape or plugs from the suction line extension fitting and the underbody suction line fitting. 17. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the underbody suction line fitting. 18. Reconnect the suction line extension fitting to the underbody suction line fitting. Tighten the fittings to 23 N.m (17 ft. lbs.). 19. Install a new tie strap just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heating-A/C system. 20. Lower the vehicle. 21. Reconnect the negative battery cable. 22. Evacuate the refrigerant system. 23. Charge the refrigerant system. Rear REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1695 NOTE: On models equipped with the rear A/C system, the rear of the front A/C suction line also includes a hose and tube extension that connects the front suction line to the underbody suction line. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Remove the air cleaner top cover and snorkel from the air cleaner housing located on the right side of the engine compartment. 4. Disconnect the drain tube from the wiper module drain on the right side of the engine compartment. 5. Remove the nut that secures the suction line to the A/C compressor. 6. Disconnect the suction line from the A/C compressor and remove and discard the seal. 7. Install plugs in, or tape over the opened suction line fitting and the compressor port. Suction Line 8. Disengage the retainer that secures the suction line routing clip to the receiver/drier mounting bracket on the side of the right front strut tower in the engine compartment. 9. Remove the nut that secures the suction and liquid lines to the front A/C expansion valve. 10. Disconnect the suction and liquid lines from the front A/C expansion valve and remove and discard the O-ring seals. 11. Install plugs in, or tape over the opened suction and liquid line fittings and expansion valve ports. 12. Raise and support the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1696 Underbody Line Connections 13. Remove the tie strap and disconnect the suction line extension fitting from the underbody suction line and remove and discard the O-ring seal. 14. Install plugs in, or tape over the opened suction line fittings. 15. Lower the vehicle. INSTALLATION 1. Position the suction line into the engine compartment. 2. Remove the tape or plugs from the suction and liquid line fittings and expansion valve ports. 3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the suction and liquid line fittings. 4. Connect the suction and liquid lines to the front A/C expansion valve. 5. Install the nut that secures the suction and liquid lines to the front A/C expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.). 6. Engage the retainer that secures the suction line routing clip to the receiver/drier mounting bracket on the side of the right front strut tower in the engine compartment. 7. Remove the tape or plugs from the A/C compressor port and the suction line fitting. 8. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the suction line fitting. 9. Connect the suction line to the A/C compressor. 10. Install the nut that secures the suction line to the A/C compressor. Tighten the nut to 23 N.m (17 ft. lbs.). 11. Connect the drain tube to the wiper module drain on the right side of the engine compartment. 12. Install the air cleaner top cover and snorkel onto the air cleaner housing located on the right side of the engine compartment. 13. Reconnect the negative battery cable. 14. Raise and support the vehicle. 15. Remove the tape or plugs from the suction line extension fitting and the underbody suction line. 16. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the underbody suction line. 17. Connect the suction line extension fitting to the underbody suction line. Tighten the fitting to 23 N.m (17 ft. lbs.). 18. Install a new tie strap just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heating-A/C system. 19. Lower the vehicle. 20. Evacuate the refrigerant system. 21. Charge the refrigerant system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1697 Hose/Line HVAC: Service and Repair Underbody Lines Underbody Heater Tubes REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Drain the engine cooling system. 2. Raise and support vehicle. Underbody Heater Tube Quick Connect Fittings 3. Disconnect the underbody heater tubes at the rear of the vehicle by releasing the insert in the underbody heater tube quick connect fittings and carefully pulling downward on the heater tube fittings. 4. Lower the underbody heater tubes and drain any residual coolant from the tubes into a suitable container. Underbody Connections Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1698 5. Using spring tension clamp pliers, compress and slide the clamps off of the rubber hoses at the front of the underbody heater tubes. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes, causing an engine coolant leak. 6. Disconnect the heater hoses by carefully twisting the hoses back and forth on the rear heater extension tubes, while gently pulling them away from the end of the tubes. 7. If necessary, carefully cut the hose ends and peel the hoses off of the tubes. NOTE: Replacement of the heater hoses will be required if the hose ends are cut for removal. 8. Remove the screws that secure the underbody line retaining straps to the vehicle underbody. 9. Remove the underbody heater tubes from the retaining straps. 10. Remove the underbody heater tubes from the vehicle. INSTALLATION 1. Position the underbody heater tubes onto the vehicle underbody. 2. Install the underbody heater tubes into the underbody line retaining straps. 3. Install the bolts that secure the retaining straps to the vehicle underbody. Tighten the screws securely. 4. Connect the rubber hoses at the front of the underbody heater tubes to the rear heater extension tubes. 5. Using spring tension clamp pliers, compress and slide the clamps that secure the heater hoses over the extension tubes. Release the clamp when it is correctly positioned over the tube. 6. Connect the rear underbody heater tube quick connections to the rear heater core extension tubes. 7. Lower the vehicle. 8. Refill the engine cooling system. Underbody Refrigerant Line REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Raise and support vehicle. 3. Disconnect the exhaust system from the exhaust hanger rubber isolators and position the exhaust system out of the way. Underbody A/C Line Front Connections - Typical 4. Disconnect the underbody refrigerant lines from the front liquid and suction line extension tubes and remove and discard the O-ring seals. 5. Install plugs in, or tape over the opened refrigerant line fittings. 6. Remove the screws that secure the underbody line retaining straps to the vehicle underbody. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1699 7. Remove the underbody refrigerant lines from the retaining straps. Underbody A/C Line Rear Connections - With New Seating Element Underbody A/C Line Rear Connections - Without New Seating Element 8. Remove the bolt or nut (depending on application) that secures the underbody refrigerant lines to the rear evaporator extension line tapping plate, located behind the right rear wheel housing. 9. Disconnect the underbody refrigerant lines from the rear evaporator extension line tapping plate and remove and discard the O-ring seals. 10. Install plugs in, or tape over the opened underbody refrigerant line fittings and the rear evaporator extension line ports. 11. Remove the underbody refrigerant lines from the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 1700 Underbody A/C Line Sealing Plate - Typical 12. If required, place the underbody refrigerant lines on a workbench, remove the nylon wedges that secure the underbody refrigerant lines to the underbody refrigerant line sealing plate and remove the lines from the sealing plate. INSTALLATION 1. If removed, install the underbody refrigerant lines into the underbody refrigerant line sealing plate and install the nylon wedges that secure the refrigerant lines to the sealing plate. 2. Position the underbody refrigerant lines onto the vehicle underbody. 3. Install the underbody refrigerant lines into the underbody line retaining straps. 4. Install the bolts that secure the retaining straps to the vehicle underbody. Tighten the screws securely. 5. Remove the tape or plugs from the rear underbody refrigerant line fittings and the rear evaporator extension line ports. 6. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the underbody refrigerant line fittings. 7. Connect the underbody refrigerant lines to the rear evaporator extension line tapping plate. 8. Install the bolt or nut (depending on application) that secures the underbody refrigerant line sealing plate to the rear evaporator extension line tapping plate. Tighten the bolt or nut to 23 N.m (17 ft. lbs.). 9. Remove the tape or plugs from the front liquid and suction line extension tubes and the underbody refrigerant line fittings. 10. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the underbody refrigerant line fittings. 11. Connect the underbody refrigerant line fittings to the front liquid and suction line extension tubes. Tighten the fittings to 23 N.m (17 ft. lbs.). 12. Position the exhaust system and install it to the exhaust hanger rubber isolators. 13. Lower the vehicle. 14. Evacuate the refrigerant system. 15. Charge the refrigerant system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder Power Steering Line/Hose: Customer Interest Steering - Low Speed Steering Shudder NUMBER: 19-006-05 GROUP: Steering DATE: August 4, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-004-03, DATED AUGUST 29, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Steering Shudder OVERVIEW: This bulletin involves replacing one of the two power steering cooler hoses with a new longer power steering hose and if necessary, installing a fin packed power steering cooler. MODELS: 2001 - 2005 (RS) Town & Country, Caravan, Voyager 2001 - 2005 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to right hand and left hand drive vehicles equipped with a 3.3L or 3.8L engine (sales code EGA, EGM, EGH) built on or before December 8, 2004 (MDH 1208XX) SYMPTOM/CONDITION: A shudder (vibration) is felt inside the vehicle while turning the steering wheel at idle or during low speeds such as a parking lot maneuver. The shudder may be felt in the steering wheel, seat, and/or body. DIAGNOSIS: 1. Verify the condition: - Perform stationary turns and/or low speed turns in drive and reverse. Perform the evaluation with the A/C in the on and off position. Is steering shudder detected? a. Yes » Go to Step # 2. b. No» Further diagnosis is needed, this bulletin does not apply. 2. Inspect for the presence of a power steering finned cooler. Is a finned cooler present? a. Yes » Go to "Replace Power Steering Hose - Step # 1". b. No. » Go to "Install Finned Cooler - Step # 1". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 1709 PARTS REQUIRED INSTALL FINNED COOLER: CAUTION: Throughout the following procedure, special care should be taken to prevent introducing contamination into the power steering system. 1. Open the hood. 2. Remove the cap from the power steering fluid reservoir. 3. Using a siphon pump/suction gun, remove as much power steering fluid as possible from the power steering fluid reservoir. 4. Remove and save the constant tension spring clamp securing the power steering return line hose to the power steering fluid reservoir. 5. Remove the rubber hose portion of the power steering return line from the power steering fluid reservoir fitting. 6. Drain the power steering fluid reservoir into an appropriate container. NOTE: This fluid should not be reused to avoid introducing contamination from the container. 7. Raise the vehicle on an appropriate hoist. 8. Remove the fuel vapor canister. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 1710 9. Locate the bracket connecting the power steering return line cooler loop to the cradle reinforcement plate (Fig. 1). 10. Remove the fasteners connecting the cooler line to the reinforcement plate. Save the fasteners for use in Step # 17. 11. Locate the bracket connecting the power steering pressure line to the cradle reinforcement plate (Fig. 1). 12. Remove the fastener connecting the bracket to the reinforcement plate. Save the fastener for use in Step # 18. 13. Remove and discard the J/U nut clip on the bracket. 14. Locate and unscrew the tube nut connecting the power steering return line to the steering gear pinion housing. NOTE: The tube nut will remain loosely assembled to the power steering return line. 15. Drain the remaining fluid into an appropriate container and discard the loop cooler line that was removed from the vehicle. NOTE: This fluid should not be reused to avoid introducing contamination from the container. 16. Install the new power steering return line, p/n 04743473AE. Attach the power steering return line tube nut to the steering gear pinion housing and tighten to 27.1 - 35.0 Nm (240 - 310 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 1711 17. Reuse the fastener removed in Step # 10. Install the fastener into the left weld nut on the cooler fin pack bracket and the left hole in the cradle reinforcement plate. Tighten the fastener to 9 - 11.3 Nm (80-100 in. lbs.) (Fig. 2). 18. Line up the pressure line bracket and the right weld nut in the cooler fin pack bracket. Reuse the fastener removed in Step # 12. Install the fastener through the right hole in the cradle reinforcement plate, the fin pack bracket and the pressure line bracket. Tighten the fastener to 9 11.3 Nm (80-100 in. lbs.) (Fig. 2). 19. Install the fuel vapor canister. 20. Lower the vehicle. 21. Install the constant tension spring clamp removed in Step # 4 onto the rubber hose on the power steering return line. Slide the clamp so that it is 3 inches from the end of the rubber hose. 22. Push the end of the rubber hose portion of the power steering return line onto the power steering fluid reservoir suction port. Secure the hose by sliding the constant spring tension clamp installed on the hose in the last step, to within 6 mm (0.25 in.) of the end of the rubber hose. Be sure the hose clamp is installed past the bead on fluid reservoir fitting. 23. Check the vehicle production date. Was the vehicle built on or before September 13, 2004 (MDH 091344XX)? a. Yes » Go to "Replace Power Steering Hose - Step # 1". b. No » Go to "Steering/pump - Standard Procedure - Step # 1". REPLACE POWER STEERING HOSE: 1. Cut 850 mm (33.5 in.) of power steering hose (p/n 05135964AA) or equivalent. 2. Cut 790 mm (31 in.) of 15.9 mm (5/8 in.) or 17.5 mm (11/16 in.) convolute tubing. Place the convolute tubing around the power steering hose. 3. Open hood and remove the power steering reservoir cap. 4. Raise the vehicle on an appropriate hoist. 5. Locate the power steering cooler attached to the crossmember support. Remove the forward (closest to front of vehicle) hose from the cooler and tube. Drain the power steering fluid in an appropriate container. 6. Remove the two tension clamps from the removed hose and install on the new power steering return hose. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 1712 7. Install the new hose and tension clamp onto the power steering cooler. 8. Wrap the hose clockwise around the perimeter and on top of the power steering cooler as shown in (Fig. 3). Install the hose and tension clamp to the power steering return tube. 9. Use two tie straps to strap the return hose to the power steering cooler and pressure steering hose shown in (Fig. 3). 10. Lower vehicle and open hood. 11. Proceed to "Steering/Pump - Standard Procedure". STEERING/PUMP - STANDARD PROCEDURE WARNING: FLUID LEVEL SHOULD BE CHECKED AND ADJUSTED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING ENGINE COMPONENTS. CAUTION: Use only Mopar(R) ATF+4 Automatic Transmission Fluid (MS-9602) in power steering system. Use of other Mopar(R) power steering fluids (MS5931 and MS9933) should be avoided to ensure peak performance of the power steering system under all operating conditions. Do not overfill. Read the fluid level through the side of the power steering fluid reservoir. The fluid level should be within "FILL RANGE" when the fluid is at a temperature of approximately 21°C to 27°C (70°F to 80°F). 1. Wipe the filler cap and area clean, then remove the cap. 2. Fill the fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 3. Start the engine and let run for a few seconds, then turn the engine off. 4. Add fluid if necessary. Repeat the above steps until the fluid level remains constant after running the engine. 5. Raise the front wheels off the ground. 6. Start the engine. 7. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 1713 8. Add fluid if necessary. 9. Lower the vehicle, then turn the steering wheel slowly from lock-to-lock. 10. Stop the engine. Check the fluid level and refill as required. 11. If the fluid is extremely foamy, allow the vehicle to stabilize a few minutes, then repeat the above procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE: P8 New Part 68 Noisy Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder Power Steering Line/Hose: All Technical Service Bulletins Steering - Low Speed Steering Shudder NUMBER: 19-006-05 GROUP: Steering DATE: August 4, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-004-03, DATED AUGUST 29, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Steering Shudder OVERVIEW: This bulletin involves replacing one of the two power steering cooler hoses with a new longer power steering hose and if necessary, installing a fin packed power steering cooler. MODELS: 2001 - 2005 (RS) Town & Country, Caravan, Voyager 2001 - 2005 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to right hand and left hand drive vehicles equipped with a 3.3L or 3.8L engine (sales code EGA, EGM, EGH) built on or before December 8, 2004 (MDH 1208XX) SYMPTOM/CONDITION: A shudder (vibration) is felt inside the vehicle while turning the steering wheel at idle or during low speeds such as a parking lot maneuver. The shudder may be felt in the steering wheel, seat, and/or body. DIAGNOSIS: 1. Verify the condition: - Perform stationary turns and/or low speed turns in drive and reverse. Perform the evaluation with the A/C in the on and off position. Is steering shudder detected? a. Yes » Go to Step # 2. b. No» Further diagnosis is needed, this bulletin does not apply. 2. Inspect for the presence of a power steering finned cooler. Is a finned cooler present? a. Yes » Go to "Replace Power Steering Hose - Step # 1". b. No. » Go to "Install Finned Cooler - Step # 1". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 1719 PARTS REQUIRED INSTALL FINNED COOLER: CAUTION: Throughout the following procedure, special care should be taken to prevent introducing contamination into the power steering system. 1. Open the hood. 2. Remove the cap from the power steering fluid reservoir. 3. Using a siphon pump/suction gun, remove as much power steering fluid as possible from the power steering fluid reservoir. 4. Remove and save the constant tension spring clamp securing the power steering return line hose to the power steering fluid reservoir. 5. Remove the rubber hose portion of the power steering return line from the power steering fluid reservoir fitting. 6. Drain the power steering fluid reservoir into an appropriate container. NOTE: This fluid should not be reused to avoid introducing contamination from the container. 7. Raise the vehicle on an appropriate hoist. 8. Remove the fuel vapor canister. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 1720 9. Locate the bracket connecting the power steering return line cooler loop to the cradle reinforcement plate (Fig. 1). 10. Remove the fasteners connecting the cooler line to the reinforcement plate. Save the fasteners for use in Step # 17. 11. Locate the bracket connecting the power steering pressure line to the cradle reinforcement plate (Fig. 1). 12. Remove the fastener connecting the bracket to the reinforcement plate. Save the fastener for use in Step # 18. 13. Remove and discard the J/U nut clip on the bracket. 14. Locate and unscrew the tube nut connecting the power steering return line to the steering gear pinion housing. NOTE: The tube nut will remain loosely assembled to the power steering return line. 15. Drain the remaining fluid into an appropriate container and discard the loop cooler line that was removed from the vehicle. NOTE: This fluid should not be reused to avoid introducing contamination from the container. 16. Install the new power steering return line, p/n 04743473AE. Attach the power steering return line tube nut to the steering gear pinion housing and tighten to 27.1 - 35.0 Nm (240 - 310 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 1721 17. Reuse the fastener removed in Step # 10. Install the fastener into the left weld nut on the cooler fin pack bracket and the left hole in the cradle reinforcement plate. Tighten the fastener to 9 - 11.3 Nm (80-100 in. lbs.) (Fig. 2). 18. Line up the pressure line bracket and the right weld nut in the cooler fin pack bracket. Reuse the fastener removed in Step # 12. Install the fastener through the right hole in the cradle reinforcement plate, the fin pack bracket and the pressure line bracket. Tighten the fastener to 9 11.3 Nm (80-100 in. lbs.) (Fig. 2). 19. Install the fuel vapor canister. 20. Lower the vehicle. 21. Install the constant tension spring clamp removed in Step # 4 onto the rubber hose on the power steering return line. Slide the clamp so that it is 3 inches from the end of the rubber hose. 22. Push the end of the rubber hose portion of the power steering return line onto the power steering fluid reservoir suction port. Secure the hose by sliding the constant spring tension clamp installed on the hose in the last step, to within 6 mm (0.25 in.) of the end of the rubber hose. Be sure the hose clamp is installed past the bead on fluid reservoir fitting. 23. Check the vehicle production date. Was the vehicle built on or before September 13, 2004 (MDH 091344XX)? a. Yes » Go to "Replace Power Steering Hose - Step # 1". b. No » Go to "Steering/pump - Standard Procedure - Step # 1". REPLACE POWER STEERING HOSE: 1. Cut 850 mm (33.5 in.) of power steering hose (p/n 05135964AA) or equivalent. 2. Cut 790 mm (31 in.) of 15.9 mm (5/8 in.) or 17.5 mm (11/16 in.) convolute tubing. Place the convolute tubing around the power steering hose. 3. Open hood and remove the power steering reservoir cap. 4. Raise the vehicle on an appropriate hoist. 5. Locate the power steering cooler attached to the crossmember support. Remove the forward (closest to front of vehicle) hose from the cooler and tube. Drain the power steering fluid in an appropriate container. 6. Remove the two tension clamps from the removed hose and install on the new power steering return hose. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 1722 7. Install the new hose and tension clamp onto the power steering cooler. 8. Wrap the hose clockwise around the perimeter and on top of the power steering cooler as shown in (Fig. 3). Install the hose and tension clamp to the power steering return tube. 9. Use two tie straps to strap the return hose to the power steering cooler and pressure steering hose shown in (Fig. 3). 10. Lower vehicle and open hood. 11. Proceed to "Steering/Pump - Standard Procedure". STEERING/PUMP - STANDARD PROCEDURE WARNING: FLUID LEVEL SHOULD BE CHECKED AND ADJUSTED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING ENGINE COMPONENTS. CAUTION: Use only Mopar(R) ATF+4 Automatic Transmission Fluid (MS-9602) in power steering system. Use of other Mopar(R) power steering fluids (MS5931 and MS9933) should be avoided to ensure peak performance of the power steering system under all operating conditions. Do not overfill. Read the fluid level through the side of the power steering fluid reservoir. The fluid level should be within "FILL RANGE" when the fluid is at a temperature of approximately 21°C to 27°C (70°F to 80°F). 1. Wipe the filler cap and area clean, then remove the cap. 2. Fill the fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 3. Start the engine and let run for a few seconds, then turn the engine off. 4. Add fluid if necessary. Repeat the above steps until the fluid level remains constant after running the engine. 5. Raise the front wheels off the ground. 6. Start the engine. 7. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 1723 8. Add fluid if necessary. 9. Lower the vehicle, then turn the steering wheel slowly from lock-to-lock. 10. Stop the engine. Check the fluid level and refill as required. 11. If the fluid is extremely foamy, allow the vehicle to stabilize a few minutes, then repeat the above procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE: P8 New Part 68 Noisy Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure Power Steering Line/Hose: Service and Repair Hose - Pressure HOSE - POWER STEERING PRESSURE REMOVAL - 3.3L/3.8L ENGINE NOTE: Before proceeding, review all WARNINGS and CAUTIONS. 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from power steering fluid reservoir. 3. Raise vehicle. 4. Remove front emissions vapor canister. 5. Remove two bolts securing pressure hose routing clamps to suspension cradle crossmember and steel reinforcement (Fig. 21). 6. Place an oil drain pan under vehicle to catch draining power steering fluid. 7. Disconnect pressure hose at power steering gear (Fig. 21). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 1726 8. Remove pressure hose routing bracket bolt at engine (Fig. 22). Bolt can be accessed through hole in cradle crossmember (Fig. 23). 9. Disconnect pressure hose tube nut at power steering pump (Fig. 22). 10. Remove power steering fluid pressure hose from vehicle. INSTALLATION 1. Remove any used O-rings from ends of power steering hose. 2. Using a lint free towel, wipe clean hose ends, power steering pump pressure outlet fitting and steering gear port. 3. Install new O-rings on ends of power steering fluid pressure hose. Lubricate O-rings using clean power steering fluid. CAUTION: Use care not to bend tube ends of the power steering hoses when installing. Leaks and restrictions may occur. CAUTION: Power steering fluid hoses must remain away from the exhaust system and must not come in contact with any unfriendly surfaces on the vehicle. 4. Route hose up behind engine toward pump avoiding tight bends or kinking. 5. Install power steering pressure hose end into pump pressure outlet fitting (Fig. 22). Thread tube nut into outlet fitting, but do not tighten at this Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 1727 time. 6. Attach pressure hose routing bracket to engine (Fig. 22). Tighten bolt to 23 Nm (200 inch lbs.) torque. 7. Tighten hose tube nut at pump outlet fitting to 31 Nm (275 inch lbs.) torque. 8. Route hose behind cradle crossmember and start hose end into gear port. Do not tighten hose tube nut at this time. 9. Attach hose to suspension cradle crossmember and steel reinforcement using two routing clamps and bolts (Fig. 21). Tighten clamp bolt at steel reinforcement to 11 Nm (100 inch lbs.) torque. Tighten clamp bolt at cradle crossmember to 23 Nm (200 inch lbs.) torque. 10. Tighten hose tube nut at power steering gear port to 31 Nm (275 inch lbs.) torque. 11. Install front emissions vapor canister. 12. Lower vehicle. 13. Fill and bleed the power steering system using the Power Steering Pump Initial Operation Procedure. 14. Inspect system for leaks. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 1728 Power Steering Line/Hose: Service and Repair Hose - Return HOSE - POWER STEERING RETURN REMOVAL - 3.3L/3.8L ENGINE NOTE: Before proceeding, review all WARNINGS and CAUTIONS. 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from power steering fluid reservoir. 3. Place an oil drain pan under vehicle to catch any draining power steering fluid. 4. Remove clamp attaching return hose to power steering fluid reservoir. Disconnect hose from reservoir (Fig. 22). 5. Follow return hose downward and open retainer at ABS bracket (Fig. 21). Remove hose tube from retainer. 6. Raise vehicle. 7. Remove front emissions vapor canister. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 1729 8. Remove bolt securing return hose routing clamp to suspension cradle crossmember (Fig. 21). 9. Remove 2 bolts attaching power steering cooler to cradle crossmember reinforcement (Fig. 24). 10. Disconnect return hose at power steering gear (Fig. 21). 11. Remove power steering fluid return hose with cooler from vehicle. INSTALLATION 1. Remove any used O-rings from ends of power steering hose. 2. Using a lint free towel, wipe clean hose ends and power steering gear hose port. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 1730 3. Install a new O-ring on gear port end of power steering fluid hose. Lubricate O-ring using clean power steering fluid. CAUTION: Use care not to bend tube ends of the power steering hoses when installing. Leaks and restrictions may occur. CAUTION: Power steering fluid hoses must remain away from the exhaust system and must not come in contact with any unfriendly surfaces on the vehicle. 4. Route hose (with cooler attached) up toward reservoir avoiding tight bends or kinking. 5. Start steering gear end of hose into gear port. Do not tighten hose tube nut at this time. 6. Attach return hose tubes to suspension cradle crossmember using routing clamp and bolt (Fig. 21). Tighten clamp bolt to 23 Nm (200 inch lbs.) torque. 7. Install the power steering fluid cooler on the cradle crossmember reinforcement (Fig. 24). Install the mounting bolts and tighten to 11 Nm (100 inch lbs.). When installing mounting bolts, include pressure hose routing clamp. 8. Tighten hose tube nut at power steering gear port to 31 Nm (275 inch lbs.) torque. 9. Install front emissions vapor canister. 10. Lower vehicle. 11. Install return hose tube into retainer on ABS bracket (Fig. 21). Close the bracket. 12. Install return hose onto reservoir (Fig. 22). Slide the hose clamp into position on fluid reservoir and attach it. Be sure hose clamp in installed past bead on fluid reservoir fitting. 13. Fill and bleed power steering system using the Power Steering Pump Initial Operation Procedure. 14. Inspect system for leaks. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 1731 Power Steering Line/Hose: Service and Repair Hose - Supply HOSE - POWER STEERING SUPPLY REMOVAL - 3.3L/3.8L ENGINE NOTE: Before proceeding, review all WARNINGS and CAUTIONS. 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from power steering fluid reservoir. 3. Place an oil drain pan under vehicle to catch any draining power steering fluid. 4. Remove clamp attaching supply hose to power steering fluid reservoir. Disconnect hose from reservoir (Fig. 22). 5. Pull upward on hose routing clip releasing it from bracket on cylinder head cover (Fig. 22). NOTE: It may be necessary to remove air cleaner housing to gain greater access to supply hose at power steering pump. 6. Remove clamp attaching supply hose to power steering pump. Disconnect hose from pump and remove from vehicle (Fig. 22). INSTALLATION 1. Install supply hose onto supply fitting on power steering pump (Fig. 22). Slide the hose clamp into position on fluid reservoir and attach it. Be sure hose clamp in installed past bead on fluid reservoir fitting. 2. Align routing clip located toward center of supply hose with hole in bracket on cylinder head cover and push into place (Fig. 22). 3. Install supply hose onto reservoir (Fig. 22). Slide the hose clamp into position on fluid reservoir and attach it. Be sure hose clamp in installed past bead on fluid reservoir fitting. 4. Fill and bleed power steering system using Power Steering Pump Initial Operation Procedure. 5. Inspect system for leaks. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1737 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1738 Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 * If DOT 3 brake fluid is not available, DOT 4 or DOT 4+ is acceptable. Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1739 Brake Fluid: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brake hydraulic unit and all hydraulic fluid hoses. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1740 Brake Fluid: Service and Repair STANDARD PROCEDURE - BRAKE FLUID LEVEL CHECKING Check master cylinder reservoir fluid level a minimum of twice annually. Fluid reservoirs are marked with the words FULL and ADD to indicate proper brake fluid fill level of the master cylinder. If necessary, add brake fluid to bring the level to the bottom of the FULL mark on the side of the master cylinder fluid reservoir. Use only Mopar brake fluid or equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications. DO NOT use brake fluid with a lower boiling point, as brake failure could result during prolonged hard braking. Use only brake fluid that was stored in a tightly sealed container. DO NOT use petroleum-based fluid because seal damage will result. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid etc. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1745 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1750 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System Capacity .................................................................................................................... ...................................................... 13.4 qts. (12.6L)* * Includes heater and coolant recovery bottle filled to MAX level - Add 2.9 qts. (2.8L) if equipped with a rear heater. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1753 Coolant: Fluid Type Specifications The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol base coolant with hybrid organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. IMPORTANT: The green coolant MUST NOT BE MIXED with the orange or magenta coolants. When replacing coolant the complete system flush must be performed before using the replacement coolant. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1754 Coolant: Service Precautions CAUTION: Mixing of coolants other than specified (non-HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. If a non-HOAT coolant is introduced into the cooling system in an emergency, it should be replaced with the specified coolant as soon as possible. Do not use plain water alone or alcohol base antifreeze products. Do not use additional rust inhibitors or antirust products, as they may not be compatible with the radiator coolant and may plug the radiator. This vehicle has not been designed for use with Propylene Glycol based coolants. Use of Propylene Glycol based coolants is not recommended. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1755 Coolant: Testing and Inspection COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37 °C (-34 °F) to -46 °C (-50 °F). The use of a hydrometer or a refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A refractometer (Special Tool 8286) will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant-corrosion protection will be severely reduced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1760 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Specifications > Capacity Specifications Differential Fluid - A/T: Capacity Specifications Automatic Transaxle Service Fill ........................................................................................................................................... ...................................................... 4.0 qts. (3.8 L) 41TE Overhaul Fill ............................................................................................................................... ..................................................... 9.7 qts. (9.2 L) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1763 Differential Fluid - A/T: Fluid Type Specifications Automatic Transmission Fluid Type ......................................................................................................... Mopar ATF+4 Automatic Transmission Fluid Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Specifications > Page 1764 Differential Fluid - A/T: Testing and Inspection 41TE - Automatic Transaxle Refer to Transmission Fluid, A/T. NOTE: The 41TE automatic transaxle has a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Specifications > Page 1765 Differential Fluid - A/T: Service and Repair 41TE - Automatic Transaxle Refer to Transmission Fluid, A/T. NOTE: The 41TE automatic transaxle has a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1770 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1775 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1780 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1785 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1786 Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1787 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1788 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1789 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1790 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1791 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Automatic Transaxle Service Fill ........................................................................................................................................... ...................................................... 3.8Liters (4.0 Qt) 41TE Overhaul Fill ............................................................................................................................... ...................................................... 9.2Liters (9.7 Qt) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1794 Fluid - A/T: Fluid Type Specifications Automatic Transmission Fluid Type .............................................................................................................. Mopar ATF+4 Automatic Transmission Fluid Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Diagnosis and Testing Fluid - A/T: Testing and Inspection Diagnosis and Testing Effects of Incorrect Fluid Level DIAGNOSIS AND TESTING - EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation and varnish build up which interferes with valve and clutch operation. Foaming also causes fluid expansion, which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Fluid Contamination DIAGNOSIS AND TESTING - FLUID CONTAMINATION Transmission fluid contamination is generally a result of: * adding incorrect fluid * failure to clean dipstick and fill tube when checking level * engine coolant entering the fluid * internal failure that generates debris * overheat that generates sludge (fluid breakdown) * failure to reverse flush cooler and lines after repair * failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The transmission cooler and lines should be reverse flushed whenever a malfunction generates sludge and/or debris. The torque converter should also be replaced at the same time. Failure to flush the cooler and lines will result in recontamination. Flushing applies to auxiliary coolers as well. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Causes of Burnt Fluid DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged main cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Diagnosis and Testing > Page 1797 Fluid - A/T: Testing and Inspection Fluid Level and Condition Check 41TE - Automatic Transaxle FLUID LEVEL AND CONDITION CHECK NOTE: Only transmission fluid of the type labeled Mopar ATF+4 (Automatic Transmission Fluid-Type 9602) should be used in this transaxle. FLUID LEVEL CHECK The transmission sump has a fluid level indicator (dipstick) to check oil similar to most automatic transmissions. It is located on the left side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P Park and N Neutral positions. Place the selector lever in P Park to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature 82° C (180° F), the fluid level is correct if it is in the HOT region on the oil level indicator (Fig. 210). The fluid level should be within the COLD region of the dipstick at 27° C (80° F) fluid temperature. FLUID LEVEL CHECK USING DRB NOTE: Engine and Transaxle should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Hook up DRB scan tool and select transmission. 3. Select sensors. 4. Read the transmission temperature value. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Diagnosis and Testing > Page 1798 5. Compare the fluid temperature value with the fluid temperature chart (Fig. 211). 6. Adjust transmission fluid level shown on the indicator according to the chart. 7. Check transmission for leaks. Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transaxle has too much fluid, the gears churn up foam and cause the same conditions, which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken for a leak. FLUID CONDITION Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle recondition is probably required. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. Mopar ATF+4 (Automatic Transmission Fluid Type 9602) when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 40TE Fluid - A/T: Service and Repair 40TE Fluid Level and Condition Check FLUID LEVEL AND CONDITION CHECK NOTE: Only transmission fluid of the type labeled Mopar ATF+4 (Automatic Transmission Fluid) should be used in this transaxle. FLUID LEVEL CHECK The transmission sump has a fluid level indicator (dipstick) to check oil similar to most automatic transmissions. It is located on the left side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P Park and N Neutral positions. Place the selector lever in P Park to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature 82° C (180° F), the fluid level is correct if it is in the HOT region on the oil level indicator (Fig. 187). The fluid level should be within the COLD region of the dipstick at 27° C (80° F) fluid temperature. FLUID LEVEL CHECK USING ORB NOTE: Engine and Transaxle should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Hook up DRB scan tool and select transmission. 3. Select sensors. 4. Read the transmission temperature value. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 40TE > Page 1801 5. Compare the fluid temperature value with the fluid temperature chart (Fig. 188). 6. Adjust transmission fluid level shown on the indicator according to the chart. 7. Check transmission for leaks. Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transaxle has too much fluid, the gears churn up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken for a leak. FLUID CONDITION Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle recondition is probably required. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. Mopar ATF+4 (Automatic Transmission Fluid) when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Fluid and Filter Service STANDARD PROCEDURE - FLUID AND FILTER SERVICE NOTE: Refer to the maintenance schedules in LUBRICATION and MAINTENANCE, or the vehicle owner's manual, for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: Only fluids of the type labeled leopard ATF+4 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed. FLUID/FILTER SERVICE (RECOMMENDED) 1. Raise vehicle on a hoist. Refer to LUBRICATION and MAINTENANCE for proper procedures. Place a drain container with a large opening, under transaxle oil pan. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 40TE > Page 1802 2. Remove both engine mount-to-engine crossmember cradle nuts. Using suitable screw jack and wood block, raise engine and transmission slightly to facilitate transaxle oil pan removal and installation. 3. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 4. Install a new filter and o-ring on bottom of the valve body (Fig. 189). 5. Clean the oil pan and magnet. Reinstall pan using new Mopar Silicone Adhesive sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 6. Pour four quarts of Mopar ATF+4 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick (Fig. 190). 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). Refer to Fluid Level and Condition Check for the proper fluid fill procedure. 10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE) 1. When performing the fluid suction method, make sure the transaxle is at full operating temperature. 2. To perform the dipstick tube fluid suction method, use a suitable fluid suction device (Vacula TM or equivalent). 3. Insert the fluid suction line into the dipstick tube. NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will ensure complete evacuation of the fluid in the pan. 4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5. Remove the suction line from the dipstick tube. 6. Pour four quarts of Mopar ATF+4 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 40TE > Page 1803 position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3mm (1/8 inch) below the lowest mark on the dipstick (Fig. 190). 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). 10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 40TE > Page 1804 Fluid - A/T: Service and Repair 41TE 41TE - Automatic Transaxle FLUID LEVEL AND CONDITION CHECK NOTE: Only transmission fluid of the type labeled Mopar ATF+4 (Automatic Transmission Fluid-Type 9602) should be used in this transaxle. FLUID LEVEL CHECK The transmission sump has a fluid level indicator (dipstick) to check oil similar to most automatic transmissions. It is located on the left side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P Park and N Neutral positions. Place the selector lever in P Park to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature 82° C (180° F), the fluid level is correct if it is in the HOT region on the oil level indicator (Fig. 210). The fluid level should be within the COLD region of the dipstick at 27° C (80° F) fluid temperature. FLUID LEVEL CHECK USING DRB NOTE: Engine and Transaxle should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Hook up DRB scan tool and select transmission. 3. Select sensors. 4. Read the transmission temperature value. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 40TE > Page 1805 5. Compare the fluid temperature value with the fluid temperature chart (Fig. 211). 6. Adjust transmission fluid level shown on the indicator according to the chart. 7. Check transmission for leaks. Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transaxle has too much fluid, the gears churn up foam and cause the same conditions, which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken for a leak. FLUID CONDITION Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle recondition is probably required. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. Mopar ATF+4 (Automatic Transmission Fluid Type 9602) when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1810 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1815 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1820 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential DIFFERENTIAL ASSEMBLY FLUID The correct fill level is to the bottom of the fill plug hole. Be sure the vehicle is on a level surface, or is hoisted in a level manner, in order to obtain the correct fill level. Drain & Fill Using a suction gun or equivalent, fill the differential assembly with 0.7 Liters (1.48 Pt) Overrunning Clutch OVERRUNNING CLUTCH HOUSING FLUID Drain & Fill Using a suction gun add 0.58 Liters (1.22 Pt) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1823 Fluid - Differential: Fluid Type Specifications Differential DIFFERENTIAL ASSEMBLY FLUID Checking Fluid The correct fill level is to the bottom of the fill plug hole. Be sure the vehicle is on a level surface, or is hoisted in a level manner, in order to obtain the correct fill level. Drain & Fill Using a suction gun or equivalent, fill the differential assembly with 0.7 L (1.48 Pt) Lubricant ...................................................................................................................................................... Mopar SAE 80W-90 Gear and Axle Lubricant Overrunning Clutch OVERRUNNING CLUTCH HOUSING FLUID Drain & Fill Using a suction gun add 0.58 L (1.22 Pt) Lubricant ................................................................................................................................ Mopar ATF+4 (Automatic Transmission Fluid - Type 9602) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Differential Assembly Fluid Drain and Fill Fluid - Differential: Service and Repair Differential Assembly Fluid Drain and Fill STANDARD PROCEDURE - DIFFERENTIAL ASSEMBLY FLUID DRAIN AND FILL The drain plug (Fig. 40) for the differential assembly is located in the bottom of the differential assembly case, toward the rear of the unit. The fill plug (Fig. 41) for the differential assembly is located on the rear of the assembly case. The correct fill level is to the bottom of the fill plug hole. Be sure the vehicle is on a level surface, or is hoisted in a level manner, in order to obtain the correct fill level. 1. Raise the vehicle on a hoist. 2. Position a drain pan under the differential drain plug (Fig. 40). 3. Remove the drain plug and allow the fluid to drain into the pan. 4. Install the drain plug and torque to 35 Nm (26 ft. lbs.). 5. Re-position the drain pan under the differential fill plug. 6. Remove the differential fill plug (Fig. 41). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Differential Assembly Fluid Drain and Fill > Page 1826 7. Using a suction gun (Fig. 42) or equivalent, fill the differential assembly with 0.7 Liters (1.48 pints) of Mopar Gear and Axle Lubricant (80W-90). 8. Install the fill plug and torque to 35 Nm (26 ft. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Differential Assembly Fluid Drain and Fill > Page 1827 Fluid - Differential: Service and Repair Overrunning Clutch Housing Fluid Change STANDARD PROCEDURE - OVERRUNNING CLUTCH HOUSING FLUID CHANGE 1. Raise vehicle on hoist. 2. Position a drain pan under overrunning clutch housing drain plug. 3. Remove overrunning clutch housing drain plug and drain fluid (Fig. 43). 4. Install the drain plug and torque to 30 Nm (22 ft. lbs.). 5. Re-position the drain pan under the overrunning clutch housing fill plug. 6. Remove fill plug (Fig. 44). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Service and Repair > Differential Assembly Fluid Drain and Fill > Page 1828 7. Using a suction gun (Fig. 45), add 0.58 Liters (1.22 pints) of Mopar ATF+4 (Automatic Transmission Fluid-Type 9602). 8. Install fill plug and torque to 30 Nm (22 ft. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1833 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1838 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1839 Engine Oil: Technical Service Bulletins Engine - Oil Quality/Viscosity Requirements NUMBER: 09-013-04 GROUP: Engine DATE: August 6, 2004 SUBJECT: Gasoline Engine Oil Quality And Viscosity Grades MODELS: 2005 (ND) Dakota 2005 (CS) Pacifica 2005 (DR) Ram Truck 2005 (HB) Durango 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2005 (KJ) Liberty 2005 (LX) 300/Magnum 2005 (PL) Neon 2005 (PT) PT Cruiser 2005 (RS) Town & Country/ Caravan/Voyager 2005 (TJ) Wrangler 2005 (WK) Grand Cherokee NOTE: This information applies to U.S. and Canada markets only. NOTE: For additional information and vehicles not covered by this Service Bulletin refer to the service information or the Owner Manual. DISCUSSION: This bulletin involves the engine oil to be used to service Chrysler Group gasoline engines. This symbol, found on the front of the container, means that the oil quality has been certified by the American Petroleum Institute (API) (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1840 Only use API Certified engine oils that meet the requirements of Chrysler's Material Standard MS-6395. MS-6395 contains requirements, not addressed by API Certification, that provide additional protection for Chrysler Group engines. All Chrysler Group gasoline engines, irrespective of model year, should be serviced with API Certified engine oils meeting MS-6395. Chrysler Group Engines are developed, certified and filled with engine oil of the designated viscosity grade, meeting MS-6395, and should be serviced with the correct viscosity grade engine oil. The following table contains the correct viscosity grades for the 2005 model year. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil and Filter ............................................................................................................................ ...................................................... 4.7Liters (5.0 Qt) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1843 Engine Oil: Fluid Type Specifications This Information has been updated by TSB 09-13-04. Engine Oil Type ................................................................................................................................... ....................................................................... 5W-20 Note: Only use API Certified engine oils that meet the requirements of Chrysler's Material Standard MS-6395. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check Engine Oil: Service and Repair Engine Oil Level Check ENGINE OIL LEVEL CHECK The best time to check engine oil level is after it has sat overnight, or if the engine has been running, allow the engine to be shut off for at least 5 minutes before checking oil level. Fig.102 Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading (Fig. 102). Add only when the level is at or below the ADD mark. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check > Page 1846 Engine Oil: Service and Repair Engine Oil and Filter Change ENGINE OIL AND FILTER CHANGE Change engine oil at mileage and time intervals. WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Open hood, remove oil fill cap. 3. Hoist and support vehicle on safety stands. Fig.101 4. Place a suitable drain pan under crankcase drain (Fig. 101). 5. Remove drain plug from crankcase (Fig. 101) and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 6. Remove oil filter. 7. Install and tighten drain plug in crankcase. 8. Install new oil filter. 9. Lower vehicle and fill crankcase with specified type and amount of engine oil. 10. Install oil fill cap. 11. Start engine and inspect for leaks. 12. Stop engine and inspect oil level. NOTE: Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1851 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1852 Power Steering Fluid: Technical Service Bulletins Power Steering - Additive Prohibition NUMBER: 19-010-04 GROUP: Steering DATE: November 29, 2004 SUBJECT: Power Steering Fluid Contamination MODELS: 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR/DH) Ram Truck 2004 - 2005 (HB) Durango 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004 - 2005 (KJ) Liberty 2004 - 2005 (LX) 300/Magnum 2004 - 2005 (PL) Neon/SRT4 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2004 - 2005 (ST) Sebring Coupe/Stratus Coupe 2004 - 2005 (TJ) Wrangler 2004 - 2005 (ZB) Viper DISCUSSION: Do not use fluids or supplements that contain Teflon as they will cause a restriction at the filter in the power steering fluid reservoir, causing severe damage to the steering system. The power steering fluid used in Chrysler Group vehicles is an engineered product, the addition of ANY unapproved fluids or supplements can interfere with the proper function of the fluid and cause damage to the steering system. To ensure the performance and durability of Chrysler Group steering systems, use only Mopar Power Steering Fluid +4, ATF+4 Automatic Transmission Fluid, or equivalent (MS-9602), in the power steering system. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1853 Power Steering Fluid: Specifications Use only Mopar MS9602, ATF+4 Type 9602. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1854 Power Steering Fluid: Testing and Inspection STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT INJURY FROM MOVING PARTS AND TO ENSURE ACCURATE FLUID LEVEL READING. The fluid level can be read on the exterior of the power steering fluid reservoir. The fluid level should be within the "FILL RANGE" when the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F) (Fig. 17). Before removing the power steering filler cap, wipe the reservoir filler cap free of dirt and debris. Do not overfill the power steering system. Use only Mopar ATF+4 Automatic Transmission Fluid (MS-9602) in the power steering system. CAUTION: Use only Mopar ATF+4 Automatic Transmission Fluid (MS-9602). Use of other Mopar power steering fluids (MS5931 and MS9933) should be avoided to ensure peak performance of the power steering system under all operating conditions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Information not supplied by the manufacturer. Refer to the sticker under the hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1859 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ...................................................................... R-134a Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1860 Refrigerant: Description and Operation The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure, refrigerant oil sludge or poor A/C system performance. In addition, the polyalkylene glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a refrigerant system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is equipped with R-134a refrigerant. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Front A/C Total System Fill .................................................................................................................................. ................................................. 6.1 fl. oz (180 ml) Receiver/Drier ....................................................... .................................................................................................................................. 0.8 fl. oz (25 ml) A/C Condenser .................................................................................................................................... .................................................... 1.7 fl. oz (50 ml) Front Evaporator .................................................. ................................................................................................................................... 1.7 fl. oz (50 ml) A/C Compressor ......................................................................................................................... Drain and measure the oil from the old compressor. Front and Rear A/C Total System Fill .................................................................................................................................. ................................................. 7.8 fl. oz (230 ml) Receiver/Drier ....................................................... .................................................................................................................................. 0.8 fl. oz (25 ml) A/C Condenser .................................................................................................................................... .................................................... 1.7 fl. oz (50 ml) Front Evaporator .................................................. ................................................................................................................................... 1.7 fl. oz (50 ml) Rear Evap. (including underbody lines) .................................................................................................................................................. 1.7 fl. oz (50 ml) A/C Compressor ......................................................................................................................... Drain and measure the oil from the old compressor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1865 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil ..................................................................................................................................... ................................................................ ND-8 PAG Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1866 Refrigerant Oil: Description and Operation The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, polyalkylene glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. The Denso 10S17 and 10S20 A/C compressors used in this vehicle are designed to use ND-8 PAG refrigerant oil. Use only this type of refrigerant oil the refrigerant system. After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system performance. PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 1867 Refrigerant Oil: Service and Repair REFRIGERANT OIL LEVEL When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The receiver/drier, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: The oil used in the Denso 10S17 and 10S20 A/C compressors is ND-8 PAG R-134a refrigerant oil. Only refrigerant oil of the same type should be used to service the A/C system. Do not use any other refrigerant oil. The oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the lubricant being removed during recovery. This amount of lubricant should be added back into the system. Refer to the reclaim/recycling equipment manufacturers instructions. It will not be necessary to check the oil level in the A/C compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant Oil Capacities Refrigerant oil must be added when a receiver/ drier, A/C evaporator or A/C condenser is replaced. See the Refrigerant Oil Capacities chart. When an A/C compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new A/C compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE - MASTER CYLINDER BLEEDING CAUTION: When clamping master cylinder in vise, only clamp master cylinder by its mounting flange. Do not clamp master cylinder piston rod, reservoir, seal or body. 1. Clamp master cylinder in a vise. NOTE: Use correct bleeder tubes when bleeding master cylinder. Master cylinder outlet ports vary in size and type depending on whether master cylinder is for a vehicle equipped with ABS or not. ABS equipped master cylinders require the additional use of ISO style flare adapters supplied in Special Tool Package 8822 to be used in conjunction with Bleeder Tubes, Special Tool Package 8358. 2. Attach special tools for bleeding master cylinder in the following fashion: a. For non-ABS control equipped master cylinders, thread a Bleeder Tube, Special Tool 8358-1, into each outlet port. Tighten each tube to 17 Nm (145 inch lbs.) torque. Flex bleeder tubes and place open ends into mouth of fluid reservoir as far down as possible (Fig. 47). b. For ABS equipped master cylinders, thread one Adapter, Special Tool 8822-2, in each outlet port. Tighten Adapters to 17 Nm (145 inch lbs.) torque. Next, thread a Bleeder Tube, Special Tool 8358-1, into each Adapter. Tighten each tube to 17 Nm (145 inch lbs.) torque. Flex bleeder tubes and place open ends into mouth of fluid reservoir as far down as possible (Fig. 47). NOTE: Make sure open ends of bleeder tubes stay below surface of brake fluid once reservoir is filled to proper level. 3. Fill brake fluid reservoir with Mopar brake fluid or equivalent conforming to DOT 3 (DOT 4 and DOT 4+ are acceptable) specifications. Make sure fluid level is above tips of bleeder tubes in reservoir to ensure no air is ingested during bleeding. 4. Using a wooden dowel as a pushrod (Fig. 47), slowly depress master cylinder pistons, then release pressure, allowing pistons to return to released position. Repeat several times until all air bubbles are expelled. Make sure fluid level stays above tips of bleeder tubes in reservoir while bleeding. 5. Remove bleeder tubes from master cylinder outlet ports, then plug outlet ports and install fill cap on reservoir. 6. Remove master cylinder from vise. 7. Install master cylinder on vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1872 Brake Bleeding: Service and Repair Base Brake System STANDARD PROCEDURE - BASE BRAKE BLEEDING NOTE: This bleeding procedure is only for the vehicle's base brakes hydraulic system. CAUTION: Before removing the master cylinder cover, thoroughly clean the cover and master cylinder fluid reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid reservoir. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic system. ^ Left Rear Wheel ^ Right Front Wheel ^ Right Rear Wheel ^ Left Front Wheel NOTE: When bleeding the brake system, some air may be trapped in the brake lines or valves far upstream, as much as ten feet from the bleeder screw (Fig. 1). Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. The brakes may be manually bled or pressure bled. MANUAL BLEEDING PROCEDURE NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper. NOTE: To adequately bleed the brakes using the manual bleeding procedure the rear brakes must be correctly adjusted. Prior to the manual bleeding of the brake hydraulic system, correctly adjust the rear brakes. 1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened. 2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at least 1 full turn. When the bleeder screw opens the brake pedal will drop all the way to the floor. CAUTION: "Just cracking" the bleeder screw often restricts fluid flow, allowing only a slow, weak fluid discharge of fluid. This practice will NOT get all the air out. Make sure the bleeder is opened at least 1 full turn when bleeding. 3. Release the brake pedal only after the bleeder screw is closed. 4. Repeat steps 1 through 3, four or five times, at each bleeder screw in the proper sequence. This should pass a sufficient amount of fluid to expel all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 5. Check pedal travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Continue to bleed system as necessary. 6. Perform a final adjustment of the rear brake shoes (when applicable), then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. PRESSURE BLEEDING PROCEDURE CAUTION: Use bleeder tank Special Tool C-3496-B or equivalent with Adapter, Special Tool 6921, to pressurize the hydraulic system for bleeding. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1873 Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. 1. Install the Adapter Master Cylinder Pressure Bleed Cap, Special Tool 6921 on the fluid reservoir of the master cylinder (Fig. 2). Attach the fluid hose from the pressure bleeder to the fitting on Special Tool 6921. 2. Attach a clear plastic hose to the bleeder screw at one wheel and feed the hose into a clear jar containing fresh brake fluid. 3. Open the left rear wheel bleeder screw at least one full turn or more to obtain an adequate flow of brake fluid. CAUTION: "Just cracking" the bleeder screw often restricts fluid flow, allowing only a slow, weak fluid discharge of fluid. This practice will NOT get all the air out. Make sure the bleeder is opened at least 1 full turn when bleeding. 4. After 4 to X ounces of brake fluid has been bled through the hydraulic system, and an air-free flow is maintained in the hose and jar, this will indicate a good bleed of the hydraulic system has been obtained. 5. Repeat the procedure at all the other remaining bleeder screws. 6. Check pedal travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 7. Perform a final adjustment of the rear brake shoes (when applicable), then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 1874 Brake Bleeding: Service and Repair Antilock Brake System STANDARD PROCEDURE - ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS though, particularly the ICU (HCU), should only need to be bled when the HCU is replaced or removed from the vehicle. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Under most circumstances that require the bleeding of the brakes hydraulic system, only the base brake hydraulic system needs to be bled. When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the scan tool to the Data Link Connector. The connector is located under the lower steering column cover to the left of the steering column. 3. Using the scan tool, check to make sure the CAB (MK20e) or ABM (Mk25e) does not have any fault codes stored. If it does, clear them using the scan tool. WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY FROM YOURSELF AND THE PAINTED SURFACES OF THE VEHICLE. BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN OPENED. 4. Bleed the base brake system using the standard pressure or manual bleeding procedure. 5. Using the scan tool, select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When the scan tool displays TEST COMPLETED, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. 7. Fill the master cylinder reservoir to the full level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 1879 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 1880 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Page 1881 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 1886 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 1887 Power Seat Circuit Breaker (30A) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 1892 Fuse: Locations Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 1893 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 1894 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 1895 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 1896 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 1897 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 1898 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 1899 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 1900 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 1901 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 1904 Fuse: Application and ID Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 1905 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 1906 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 1907 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 1908 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 1909 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 1910 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 1911 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 1912 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 1913 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 1918 Fuse Block: Locations Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 1919 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 1920 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 1921 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 1922 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 1923 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 1924 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 1925 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 1926 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 1927 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 1932 Fuse Block: Application and ID Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 1933 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 1934 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 1935 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 1936 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 1937 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 1938 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 1939 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 1940 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 1941 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 1946 Relay Box: Locations Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 1947 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 1948 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 1949 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 1950 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 1951 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 1952 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 1953 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 1954 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 1955 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Page 1956 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 1959 Relay Box: Application and ID Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 1960 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 1961 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 1962 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 1963 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 1964 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 1965 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 1966 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 1967 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 1968 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Service and Repair Low Tire Pressure Indicator: Service and Repair Inspect all tire for proper inflation pressure, once proper tire pressure has been set the TPM system warning will reset automatically once the ignition switch has been turned ON. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair Service Interval When this feature is selected, a service interval between 2,000 (3,200 km) and 6,000 miles (9,600 km) in 500 mile (800 km) increments may be selected. Pressing the STEP button when in this display will select distances between 2,000 (3,200 km) and 6,000 miles (9,600 km) in 500 mile (800 km) increments. Reset Service Distance (Displays Only if Service Interval was Changed) When this feature is selected the current accumulated service distance can be reset to the newly selected service interval. Pressing the STEP button when in this display will select "Yes" or "No." Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The use of tire sealants is strictly prohibited for vehicles equipped with the Tire Pressure Monitoring system. Tire sealants can clog tire pressure sensors. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. CAUTION: Any time a sensor is to be installed in a wheel, a new seal and washer must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 1981 Tire Pressure Sensor: Description and Operation SENSOR - TPM DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor is mounted to each wheel in place of the traditional tire valve stem (Fig. 18). Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency (Fig. 18). The TPM sensors are designed for original style factory wheels. Do not attempt to install a tire pressure sensor in an aftermarket wheel. The serviceable components of the tire pressure sensor are (Fig. 19): Sensor-To-Wheel Seal and Metal Washer - Valve Stem Cap - Valve Stem Core - Valve Stem Nut Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 1982 The valve stem caps and cores used are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. OPERATION The battery operated tire pressure sensors lay dormant (Park Mode), then wake and start transmitting (Drive Mode) when the vehicle first reaches speeds over 15 mph (24 km/h). Once the wheels stop rotating for a period of approximately 20 minutes, the sensors shut down until again awaken. Although not transmitting as when in Drive Mode, while in Park Mode, the sensors still transmit approximately once every 13 hours to let the receiver know air pressure status at that time. Using an RF signal, each sensor transmits tire pressure data approximately once every minute. Each sensor's (transmitter) broadcast is uniquely coded so that the Sentry Key Remote Entry Module (SKREEM) can monitor the state of each of the sensors on the four rotating road wheels. The SKREEM automatically learns and stores the sensor's ID while driving after a sensor has been replaced. There is no formal retraining procedure necessary. For additional information, refer to appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 1983 Tire Pressure Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TIRE PRESSURE SENSOR NOTE: Tire pressure may increase from 2 to 6 psi (14 to 41 kPa) during normal driving conditions. Do NOT reduce this normal pressure build up. When diagnosing a tire pressure issue, always check air pressure in the tires first with a known accurate air gauge. Adjust air pressure as necessary to that listed on the Tire Inflation Pressure Label (Placard) provided with the vehicle (usually applied to the driver's side B-pillar). After adjusting air pressure in a tire, allow approximately two minutes for the message or indicator lamp to go out. Check the tire pressure indicator lamp in the instrument cluster. If the lamp is illuminating continuously, proceed as listed. If the indicator lamp is flashing on/off three times, once every ten minutes, there is a system fault detected. Refer to the appropriate diagnostic information. If air pressure in any tire is low, inspect all the tires for leaks. A water "dunk tank" or other water test may be used to check for a leak around the sensor as long as any water at the valve core is removed once the procedure is completed. The water can be easily expelled from the core area by pushing in on the core for several seconds, allowing escaping air to drive out any moisture. Reinflate the tire as necessary. Always make sure the original valve stem cap is securely installed to keep moisture out of the sensor. If the gauge-read pressure in the tires does not indicate a tire pressure issue, refer to the appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 1984 Tire Pressure Sensor: Service and Repair TIRE PRESSURE SENSOR REMOVAL 1. Remove tire and wheel assembly from vehicle. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 2. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor. That includes both front and rear beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool at the valve stem ± 10° (Fig. 20), then proceed to dismount the tire from the wheel. Use this process on both the upper and lower tire beads. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 1985 3. Remove sensor nut retaining sensor to wheel (Fig. 21). While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 4. Remove sensor from wheel (Fig. 21). INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal and metal washer at base of valve stem to ensure proper sealing (Fig. 22). 1. Wipe area clean around sensor/valve stem mounting hole in wheel. Make sure surface of wheel is not damaged. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 1986 CAUTION: To avoid damaging sensor antenna strap (Fig. 23), hold pressure against rear of metal valve stem (Fig. 24) while sensor is inserted through wheel mounting hole and nut is installed. 2. Insert sensor through wheel as shown keeping pressure against rear of metal valve stem. (Fig. 24). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) by hand (Fig. 24). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 1987 NOTE: Before tightening sensor nut, push downward on sensor housing in an attempt to make it flush with interior contour of wheel (Fig. 25). 4. While holding sensor in position, tighten sensor nut to 6.5 Nm (58 inch lbs.) torque. CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 inch lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function, however, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem approximately 210° from the head of the changer in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire (Fig. 26). Use this procedure on both the upper and lower tire beads. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 1988 b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem is approximately 210° from the head of the changer in a clockwise direction from the mounting end of the tool (Fig. 27) Make sure the sensor is clear of the lower bead breaker area to avoid damaging the sensor when the breaker rises (Fig. 27). Rotate the tool in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install wheel and tire assembly on vehicle. 8. Drive vehicle for a minimum of five minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time the system will learn the new sensor ID code and will clear any DTCs automatically. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Service and Repair Low Tire Pressure Indicator: Service and Repair Inspect all tire for proper inflation pressure, once proper tire pressure has been set the TPM system warning will reset automatically once the ignition switch has been turned ON. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The use of tire sealants is strictly prohibited for vehicles equipped with the Tire Pressure Monitoring system. Tire sealants can clog tire pressure sensors. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. CAUTION: Any time a sensor is to be installed in a wheel, a new seal and washer must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 1996 Tire Pressure Sensor: Description and Operation SENSOR - TPM DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor is mounted to each wheel in place of the traditional tire valve stem (Fig. 18). Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency (Fig. 18). The TPM sensors are designed for original style factory wheels. Do not attempt to install a tire pressure sensor in an aftermarket wheel. The serviceable components of the tire pressure sensor are (Fig. 19): Sensor-To-Wheel Seal and Metal Washer - Valve Stem Cap - Valve Stem Core - Valve Stem Nut Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 1997 The valve stem caps and cores used are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. OPERATION The battery operated tire pressure sensors lay dormant (Park Mode), then wake and start transmitting (Drive Mode) when the vehicle first reaches speeds over 15 mph (24 km/h). Once the wheels stop rotating for a period of approximately 20 minutes, the sensors shut down until again awaken. Although not transmitting as when in Drive Mode, while in Park Mode, the sensors still transmit approximately once every 13 hours to let the receiver know air pressure status at that time. Using an RF signal, each sensor transmits tire pressure data approximately once every minute. Each sensor's (transmitter) broadcast is uniquely coded so that the Sentry Key Remote Entry Module (SKREEM) can monitor the state of each of the sensors on the four rotating road wheels. The SKREEM automatically learns and stores the sensor's ID while driving after a sensor has been replaced. There is no formal retraining procedure necessary. For additional information, refer to appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 1998 Tire Pressure Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TIRE PRESSURE SENSOR NOTE: Tire pressure may increase from 2 to 6 psi (14 to 41 kPa) during normal driving conditions. Do NOT reduce this normal pressure build up. When diagnosing a tire pressure issue, always check air pressure in the tires first with a known accurate air gauge. Adjust air pressure as necessary to that listed on the Tire Inflation Pressure Label (Placard) provided with the vehicle (usually applied to the driver's side B-pillar). After adjusting air pressure in a tire, allow approximately two minutes for the message or indicator lamp to go out. Check the tire pressure indicator lamp in the instrument cluster. If the lamp is illuminating continuously, proceed as listed. If the indicator lamp is flashing on/off three times, once every ten minutes, there is a system fault detected. Refer to the appropriate diagnostic information. If air pressure in any tire is low, inspect all the tires for leaks. A water "dunk tank" or other water test may be used to check for a leak around the sensor as long as any water at the valve core is removed once the procedure is completed. The water can be easily expelled from the core area by pushing in on the core for several seconds, allowing escaping air to drive out any moisture. Reinflate the tire as necessary. Always make sure the original valve stem cap is securely installed to keep moisture out of the sensor. If the gauge-read pressure in the tires does not indicate a tire pressure issue, refer to the appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 1999 Tire Pressure Sensor: Service and Repair TIRE PRESSURE SENSOR REMOVAL 1. Remove tire and wheel assembly from vehicle. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 2. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor. That includes both front and rear beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool at the valve stem ± 10° (Fig. 20), then proceed to dismount the tire from the wheel. Use this process on both the upper and lower tire beads. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 2000 3. Remove sensor nut retaining sensor to wheel (Fig. 21). While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 4. Remove sensor from wheel (Fig. 21). INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal and metal washer at base of valve stem to ensure proper sealing (Fig. 22). 1. Wipe area clean around sensor/valve stem mounting hole in wheel. Make sure surface of wheel is not damaged. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 2001 CAUTION: To avoid damaging sensor antenna strap (Fig. 23), hold pressure against rear of metal valve stem (Fig. 24) while sensor is inserted through wheel mounting hole and nut is installed. 2. Insert sensor through wheel as shown keeping pressure against rear of metal valve stem. (Fig. 24). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) by hand (Fig. 24). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 2002 NOTE: Before tightening sensor nut, push downward on sensor housing in an attempt to make it flush with interior contour of wheel (Fig. 25). 4. While holding sensor in position, tighten sensor nut to 6.5 Nm (58 inch lbs.) torque. CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 inch lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function, however, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem approximately 210° from the head of the changer in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire (Fig. 26). Use this procedure on both the upper and lower tire beads. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 2003 b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem is approximately 210° from the head of the changer in a clockwise direction from the mounting end of the tool (Fig. 27) Make sure the sensor is clear of the lower bead breaker area to avoid damaging the sensor when the breaker rises (Fig. 27). Rotate the tool in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install wheel and tire assembly on vehicle. 8. Drive vehicle for a minimum of five minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time the system will learn the new sensor ID code and will clear any DTCs automatically. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation Tires: Description and Operation TIRES DESCRIPTION Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain, in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: Rapid acceleration - Severe application of brakes - High-speed driving - Taking turns at excessive speeds - Striking curbs and other obstacles - Operating vehicle with over or under inflated tire pressures Radial ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval. This will help to achieve a greater tread-life potential. TIRE IDENTIFICATION Tire type, size, load index and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the Tire Identification chart to decipher the code. For example purposes, the tire size P225/60 R 16 97 T is used in the chart. An All Season type tire will also have either M + S. M & S or M - S (indicating mud and snow traction) imprinted on the side wall. An Extra or Light Load marking "XL" or "LL" may also be listed on the sidewall. The absence of an "XL" or "LL" marking infers a standard load tire. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Page 2007 TIRE IDENTIFICATION NOTE: Consult the tire manufacturer regarding any questions on tire specifications or capabilities. TIRE CHAINS Refer to the owners manual supplied with the vehicle to determine whether the use of tire chains is permitted on this vehicle. DESCRIPTION - RADIAL-PLY TIRES Radial-ply tires improve handling, tread life, ride quality and decrease rolling resistance. Radial-ply tires must always be used in sets of four and under no circumstances should they be used on the front only. It is recommended that tires from different manufacturers NOT be mixed. They may be mixed with a temporary spare tire when necessary. A maximum speed of 80 km/h (50 mph) is recommended while a temporary spare is in use. Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the same recommended inflation pressures. DESCRIPTION - REPLACEMENT TIRES WARNING: FAILURE TO EQUIP THE VEHICLE WITH TIRES HAVING ADEQUATE SPEED CAPABILITY CAN RESULT IN SUDDEN TIRE FAILURE. WARNING: IN ORDER TO MAINTAIN THE SPEED CAPABILITY OF THE VEHICLE, REPLACEMENT TIRES MUST HAVE SPEED RATINGS EQUAL TO OR HIGHER THAN THOSE FITTED TO THE VEHICLE AS ORIGINAL EQUIPMENT. IF TIRES WITH LOWER SPEED RATINGS ARE FITTED, THE VEHICLE'S HANDLING MAY BE AFFECTED AND THE SPEED CAPABILITY OF THE VEHICLE MAY BE LOWERED TO THE MAXIMUM SPEED CAPABILITY OF THE REPLACEMENT TIRES. TO AVOID AN ACCIDENT RESULTING IN SEVERE OR FATAL INJURY, CONSULT THE TIRE MANUFACTURER IN REGARDS TO MAXIMUM SPEED RATINGS. It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The original equipment tires provide a proper combination of many characteristics such as: Ride - Noise - Handling - Durability - Tread life - Traction - Rolling resistance - Speed capability The use of tires smaller than the minimum tire size approved for the vehicle can result in tire overloading and failure. Use tires that have the approved load rating for the vehicle and never overload them. Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure and loss of vehicle control. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Page 2008 The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. DESCRIPTION - SPARE TIRE (TEMPORARY) The temporary (convenience) spare tire is designed for emergency use only. The original tire should be repaired and reinstalled, or replaced with a new, at the first opportunity. The temporary (convenience) spare tire should be inflated to the pressure listed on its sidewall. Do not exceed speeds of 80 km/h (50 mph) when the temporary spare tire is in use on the vehicle. Refer to the Owner's Manual for more details. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tire Wear Patterns Tires: Testing and Inspection Tire Wear Patterns TIRE WEAR PATTERNS Under inflation will cause wear on the shoulders of tire. Over inflation will cause wear at the center of tire. Excessive camber causes the tire to run at an angle to the road. One side of tread is then worn more than the other (Fig. 29). Excessive toe-in or toe-out causes wear on the tread edges and a feathered effect across the tread (Fig. 29). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tire Wear Patterns > Page 2011 Tires: Testing and Inspection Tire/Vehicle Lead TIRE/VEHICLE LEAD Use the following Vehicle Lead Diagnosis And Correction Chart to diagnose and correct a vehicle lead or drift problem. VEHICLE LEAD DIAGNOSIS AND CORRECTION CHART Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tire Wear Patterns > Page 2012 Tires: Testing and Inspection Tread Wear Indicators TREAD WEAR INDICATORS Tread wear indicators are molded into the bottom of the tread grooves. When tread depth is 1.6 mm (1/16 inch), the tread wear indicators will appear as a 13 mm (1/2 inch) band (Fig. 30). Tire replacement is necessary when indicators appear in two or more grooves or if localized balding occurs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures Tires: Procedures Cleaning CLEANING - TIRES Before delivery of a vehicle, remove the protective coating on the tires with white sidewalls or raised white letters. To remove the protective coating, apply warm water and let it soak for a few minutes. Afterwards, scrub the coating away with a soft bristle brush. Steam cleaning may also be used to remove the coating. CAUTION: DO NOT use gasoline, mineral oil, oil-based solvent or a wire brush for cleaning. Tire Inflation Pressures STANDARD PROCEDURE - TIRE INFLATION PRESSURES The specified tire pressures have been chosen to provide safe operation, vehicle stability, and a smooth ride. The proper tire pressure specification can be found on the Tire Inflation Pressure Label provided with the vehicle (usually on the driver's side B-pillar). A quality air pressure gauge is recommended to check tire air pressure. Tire pressure should be checked cold once per month. Check tire pressure more frequently when the weather temperature varies widely. Tire pressure will decrease when the outdoor temperature drops. After checking the air pressure, replace valve cap finger tight. Inflation pressures specified on the Tire Inflation Pressure Label are always the cold inflation pressure of the tire. Cold inflation pressure is obtained after the vehicle has not been operated for at least 3 hours, or the vehicle is driven less than one mile after being inoperative for 3 hours. Tire inflation pressures may increase from 2 to 6 pounds per square inch (psi) (14 to 41 kPa) during operation. Do not reduce this normal pressure buildup. Improper inflation can cause: Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride - The vehicle to drift. WARNING: OVER OR UNDER INFLATED TIRES CAN AFFECT VEHICLE HANDLING. THE TIRE CAN FAIL SUDDENLY, RESULTING IN LOSS OF VEHICLE CONTROL. Under inflation causes rapid shoulder wear, tire flexing, and can result in tire failure (Fig. 31). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 2015 Over inflation causes rapid center wear and loss of the tire's ability to cushion shocks (Fig. 32). Tire Pressure For High Speed Operation STANDARD PROCEDURE - TIRE PRESSURE FOR HIGH SPEED OPERATION DaimlerChrysler Corporation advocates driving at safe speeds within posted speed limits. Where speed limits allow the vehicle to be driven at high speeds, correct tire inflation pressure is very important. Vehicles loaded to maximum capacity should not be driven at continuous speeds over 120 km/h (75 mph). Never exceed the maximum speed capacity of the tire. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 2016 Tires: Removal and Replacement STANDARD PROCEDURE - TIRE LEAK REPAIRING For proper repairing, a radial tire must be removed from the wheel. Repairs should only be made if the defect, or puncture, is in the tread area (Fig. 33). The tire should be replaced if the puncture is located in the sidewall. Deflate tire completely before attempting to dismount the tire from the wheel. Use a lubricant such as a mild soap solution when dismounting or mounting tire. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary. Install wheel on vehicle, and progressively tighten the 5 wheel nuts to a torque of 135 Nm (100 ft. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels Wheels: Technical Service Bulletins Wheels - Caring for Chrome Wheels NUMBER: 22-001-05 GROUP: Wheels and Tires DATE: December 1, 2005 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-004-03, DATED SEPTEMBER 26, 2003 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS AND CLEANER SUGGESTIONS. SUBJECT: Chrome Wheel Care MODELS: 2000 - 2003 (AB) Ram Van/Wagon 2002 - 2004 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2004 - **2006** (CS) Pacifica 2002 - 2003 (DN) Durango 2002 - **2006 (DR/DH) Ram Truck** 2004 - **2006** (HB) Durango 2001 - **2006** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - **2006** (KJ) Liberty 1998 - 2004 (LH) Concorde/Intrepid/LHS/300M 2005 - **2006 (LX/LE) 300/Charger/Magnum** **2005 - 2006 (ND) Dakota** 1998 - 2000 (NS) Town & Country 2002 - **2005** (PL) Neon 1999 - 2002 (PR) Prowler 2001 - **2006** (PT) PT Cruiser 2001 - **2006** (RS) Town & Country/Caravan 2001 - **2005** (ST) Sebring/Stratus Coupe 2002 - **2006** (TJ) Wrangler **2002 - 2006 (VA) Sprinter** 2001 - 2004 (WJ) Grand Cherokee **2005 - 2006 (WK/WH) Grand Cherokee** **2006 (XK) Commander** 2003 - **2006 (ZB) Viper/Viper Coupe** Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels > Page 2021 2004 - **2006 (ZH) Crossfire/Crossfire Convertible/SRT6** DISCUSSION: Chrome wheels should be cleaned regularly with **good quality car wash such as MOPAR Car Wash Concentrate p/n 04796236AB,** and water to maintain their luster and prevent corrosion. Wash them with the same soap solution as the body of the vehicle. Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to wheels. MOPAR Tire and Wheel Cleaner, p/n 05066247AB - 22 oz. or 05066248AB - 5 gal. **or MOPAR Wheel Cleaner, p/n 04796239AB,** is recommended to remove normal brake dust, dirt, grease and grime. NOTE: To clean extremely dirty wheels, MOPAR Chrome Cleaner, pin 04318013, is recommended. Any of the "DO NOT USE" items listed below can damage or stain wheels and wheel trim. DO NOT USE: ^ Wheel cleaners that contain hydroflouric acid, biflouride compounds, sulfuric acid, or phosphoric acid. ^ Any abrasive type cleaner ^ Any abrasive cleaning pad (such as steel wool) or abrasive brush ^ Any oven cleaner. ^ A car wash that has carbide tipped wheel-cleaning brushes. CAUTION: Many commercial wheel cleaners contain acids that may harm the wheel surface. Avoid all "wheel acid" type cleaners. CAUTION: Any facility found using acid based wheel cleaners will void all wheel warranties, and all damage to customer wheels will be the facility's responsibility. Refer to Global Warranty Bulletin D-01-22 for further information. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2022 Wheels: Specifications Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2023 Wheels: Description and Operation WHEELS Original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity. All models use either steel or aluminum drop-center wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps (Fig. 34). Initial inflation of the tires forces the bead over these raised sections. In case of air loss, the safety humps hold the tire in position on the wheel until the vehicle can be brought to a safe stop. Cast aluminum wheels require special balance weights to fit on the flange of the rim (Fig. 35). When wheel alignment is necessary on a vehicle with cast aluminum wheels, special wheel clamps are required to avoid damage to the wheel's finish. The wheel studs and nuts are designed for specific wheel applications and must be replaced with equivalent parts. All aluminum wheels have wheel mounting (lug) nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2024 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: - Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they must be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. WARNING: Replacement with used wheels is not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. WARNING: DaimlerChrysler Corporation does not recommend that customers use "reconditioned" wheels (wheels that have been damaged and repaired) because they can result in a sudden catastrophic wheel failure which could cause loss of control and result in injury or death. For clarification: - Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is no exposure to paint curing heat over 200 degrees Fahrenheit. - Damaged wheels are those which have been bent, broken, cracked or sustained some other physical damage which may have compromised the wheel structure. - Repaired indicates that the wheel has been modified through bending, welding, heating, straightening, or material removal to rectify damage. - Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of original equipment painted or polished wheels, as this may alter mechanical properties and affect fatigue life. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2025 Wheels: Service and Repair WHEEL AND WHEEL TRIM CARE All wheels and wheel trim, especially aluminum and chrome plated, should be cleaned regularly using mild soap and water to maintain their luster and to prevent corrosion. Wash them with the same soap solution recommended for the body of the vehicle. When cleaning extremely dirty wheels, care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to the wheels. Mopar Wheel Treatment or Mopar Chrome Cleaner is recommended. Any of the "DO NOT USE" items listed below can damage wheels and wheel trim. DO NOT USE: Any abrasive cleaner - Any abrasive cleaning pad (such as steel wool) or abrasive brush - Any cleaner that contains an acid which can react with and discolor the chrome surface. Many wheel cleaners contain acids that can harm the wheel surface. - Oven cleaner - A car wash that uses carbide-tipped wheel cleaning brushes or acidic solutions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Hub And Bearing Mounting Bolts Front .................................................................................................................................................... ................................................. 65 Nm (45 ft. lbs.) Rear ..................................................................... ............................................................................................................................... 129 Nm (95 ft. lbs.) Hub And Bearing Axle Hub Nut .......................................................................................................................................................... 244 Nm (180 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Wheel Bearing: Description and Operation Front HUB AND BEARING DESCRIPTION The front wheel bearing and front wheel hub of this vehicle are a hub and bearing unit type assembly (Unit III). This unit combines the front wheel mounting hub (flange) and the front wheel bearing into a sealed one-piece unit. The hub and bearing is mounted to the center of the steering knuckle. It is retained by four mounting bolts accessible from the inboard side of the steering knuckle. The hub flange has five wheel mounting studs. The wheel mounting studs used to mount the tire and wheel to the vehicle are the only replaceable components of the hub and bearing assembly. Otherwise, the hub and bearing is serviced only as a complete assembly. OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the driveshaft, along with the tire and wheel. The five wheel mounting studs mount the tire and wheel, and brake rotor to the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front > Page 2031 Wheel Bearing: Description and Operation Rear HUB AND BEARING DESCRIPTION The rear wheel bearing and rear wheel hub of this vehicle are a one-piece sealed unit, or hub and bearing unit type assembly (Unit III). The hub and bearing is mounted to the center of the rear axle using 4 mounting bolts. It has five wheel mounting studs on the hub flange. All Wheel Drive vehicles have a hub and bearing unit with a splined hole in the center of the hub for rear driveshaft stub axle acceptance. Front Wheel Drive vehicles with antilock brakes have an internally mounted wheel speed sensor and tone wheel. This hub and bearing can be identified by the rounded cap and molded in connector on the rear of the assembly. The sensor and tone wheel cannot be serviced separately from the hub and bearing. OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the tire and wheel assembly (and driveshaft on All-Wheel-Drive vehicles). The five wheel mounting studs mount the tire and wheel assembly, and disc brake rotor or brake drum to the vehicle. On All Wheel Drive vehicles, the splined mating of the driveshaft stub axle and hub allows the driveshaft to rotate with the hub and wheel. Front Wheel Drive vehicles equipped with antilock brakes have a wheel speed sensor and tone wheel mounted to the rear of the hub and bearing. The tone wheel rotates with the hub which is sensed by the wheel speed sensor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front DIAGNOSIS AND TESTING - HUB AND BEARING The condition of the front hub and bearing assembly is diagnosed using the inspection and testing procedure. The bearing contained in the Unit III front hub/bearing assembly will produce noise and vibration when worn or damaged. The noise will generally change when the bearings are loaded. A road test of the vehicle is normally required to determine the location of a worn or damaged bearing. Find a smooth level road surface and bring the vehicle up to a constant speed. When vehicle is at a constant speed, swerve the vehicle back and forth from the left and to the right. This will load and unload the bearings and change the noise level. When bearing damage is slight, the noise is sometimes noticeable at lower speeds and at other times is more noticeable at speeds above 105 km/h (65 mph). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 2034 Wheel Bearing: Testing and Inspection Rear DIAGNOSIS AND TESTING - HUB AND BEARING The bearing contained in the hub and bearing assembly will produce noise and vibration when worn or damaged. The noise will generally change when the bearings are loaded. A road test of the vehicle is normally required to determine the location of a worn or damaged bearing. Find a smooth level road surface and bring the vehicle up to a constant speed. When vehicle is at a constant speed, swerve the vehicle back and forth from the left and to the right. This will load and unload the bearings and change the noise level. When bearing damage is slight, the noise is sometimes noticeable at lower speeds and at other times is more noticeable at speeds above 105 km/h (65 mph). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front REMOVAL NOTE: Replacement of the Unit III front hub/bearing assembly can be normally done without having to remove the steering knuckle from the vehicle. In the event that the hub/bearing is frozen in the steering knuckle and cannot be removed by hand, it will have to be pressed out of the steering knuckle. The steering knuckle will require removal from the vehicle to allow the hub/bearing assembly to be pressed out of the steering knuckle. 1. Raise vehicle. 2. Remove wheel lug nuts, and front tire and wheel assembly. 3. Remove the cotter pin, nut lock and spring washer from the stub axle. 4. With aid of a helper applying the brakes to keep the front hub from turning, remove the hub nut. 5. Remove disc brake caliper and adapter as an assembly from knuckle as shown. Hang assembly out of the way using a bungee cord or wire. Do not allow caliper hang by brake hose. 6. Remove brake rotor from hub and bearing. 7. Push in on end of driveshaft stub shaft, pushing its splines out of the hub splines. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2037 8. Remove the four hub and bearing mounting bolts from the rear of steering knuckle. Use care not to come in contact with and damage the ABS tone wheel on the driveshaft stub shaft upon bolt removal. 9. Remove the hub and bearing assembly from the steering knuckle. INSTALLATION CAUTION: Hub and bearing assembly mounting surfaces on the steering knuckle and stub axle must be smooth and completely free of foreign material or nicks prior to installing hub and bearing assembly. CAUTION: When installing hub and bearing into steering knuckle, be careful not to damage the bearing seal on the outer C/V joint. 1. Install hub and bearing onto stub axle and into steering knuckle until squarely seated on the face of the steering knuckle. 2. Install the 4 hub and bearing mounting bolts from the rear of the knuckle. Equally tighten all 4 mounting bolts in a cries-cross pattern until hub/bearing assembly is squarely seated against front of steering knuckle. Tighten mounting bolts to a torque of 65 Nm (45 ft. lbs.) 3. Install the brake rotor on the hub and bearing. 4. Install brake caliper and adapter assembly back over brake rotor and align with mounting holes on steering knuckle. Install the mounting bolts and tighten to 169 Nm (125 ft. lbs.) torque. 5. Install the hub nut on the end of the stub axle. With aid of a helper applying the brakes to keep the front hub from turning, tighten the hub nut to Install the mounting bolts and tighten to 244 Nm (180 ft. lbs.) torque. 6. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 7. Lower vehicle to the ground. 8. Check the front wheel alignment toe setting and reset if not within specifications. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2038 Wheel Bearing: Service and Repair Rear REMOVAL - FWD 1. Raise vehicle. 2. Remove wheel and tire. 3. Remove brake drum or disc brake caliper and rotor from hub and bearing. 4. If equipped with antilock brakes, perform the following: a. Remove secondary (yellow) retaining clip at rear of wheel speed sensor head. b. Push up on metal retaining clip until it bottoms. This will release wheel speed sensor head from hub and bearing. c. While holding metal clip up, pull back on wheel speed sensor head removing it from hub and bearing. 5. Remove the 4 bolts attaching the hub and bearing to the rear axle. CAUTION: Corrosion may occur between the hub and bearing, and the axle. If this occurs the hub and bearing will be difficult to remove from the axle. If the hub and bearing will not come out of the axle by pulling on it by hand, do not pound on the hub and bearing to remove it from the axle. Damage will occur. Use the following procedure. 6. If the hub and bearing cannot be removed from the axle by hand, use Remover, Special Tool 8458 and the following procedure to press the hub and bearing out of the axle. a. Remove the two outboard spring plate bolts. b. Thread Threaded Guide Pins into hub and bearing mounting bolt holes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2039 c. Using the spring plate bolts, install the Screw Mount, Special Tool 8458-2, as shown. Mount the Screw Mount to the spring plate with the tool number facing the hub and bearing and the beveled edge on the bottom facing the spring, otherwise the Forcing Screw will rub the spring plate when installed. d. Place Push Plate, Special Tool 8458-1, on ends of Threaded Guide Pins e. Place a dab of grease in dimple of Push Plate. f. Install Forcing Screw, Special Tool 8458-3, through Screw Mount from rear. g. Tighten the Forcing Screw up against dimple in Push Plate and press hub and bearing out of axle by continuing to tighten screw. h. Remove the tool. i. Reinstall the two outboard spring plate bolts. Tighten the bolts to 102 Nm (75 ft. lbs.) torque. 7. Remove the hub/bearing from the rear axle and brake support plate. INSTALLATION - FWD 1. Install the 4 hub and bearing to axle mounting bolts into the holes in the flange of the rear axle. 2. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. 3. Align the rear hub and bearing with the 4 mounting bolts and start mounting bolts into hub and bearing. Tighten the 4 bolts in a crisscross pattern until the hub and bearing and brake support plate is fully and squarely seated onto flange of rear axle. Tighten the 4 mounting bolts to a torque of 129 Nm (95 ft. lbs.) NOTE: If equipped with antilock brakes, make sure wheel speed sensor stays clean and dry as it is installed into the hub and bearing cap. 4. If the vehicle is equipped with antilock brakes, perform the following: a. If metal sensor retaining clip is not in the neutral installed position on hub and bearing cap, install from the bottom, if necessary, and push clip upward until it snaps into position. b. Install wheel speed sensor head into rear of hub and bearing aligning index tab with the notch in the top of the mounting hole. Push the sensor in until it snaps into place on the metal retaining clip. c. Install secondary (yellow) retaining clip over wheel speed sensor head and engage the tabs on each side. 5. Install brake drum or disc brake rotor and brake caliper. 6. Install wheel and tire. Tighten the wheel nuts in the proper sequence to a torque of 135 Nm (100 ft. lbs.). 7. Adjust the rear brakes as necessary. 8. Lower vehicle. 9. Road test vehicle to ensure proper operation of brakes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Description and Operation Wheel Cover: Description and Operation WHEEL COVER This vehicle uses a bolt-on type wheel cover (Fig. 36). This bolt-on wheel cover cannot be removed from the wheel until three of the five wheel mounting nuts shown are removed (Fig. 36). The bolt-on wheel cover can then be removed with the remaining two wheel nuts tightened in place. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Description and Operation > Page 2043 Wheel Cover: Service and Repair WHEEL COVER REMOVAL 1. Noting the location of the valve stem in relationship to the wheel mounting nuts, remove the three wheel mounting nuts securing the wheel cover to the wheel and hub (Fig. 36). CAUTION: When removing the wheel cover, do not pry the wheel cover from the wheel. This can result in damage to the wheel cover. The wheel cover is removed by pulling it off the wheel by hand. 2. Grasp the wheel cover at the edges in line with the remaining installed wheel nuts and pull straight outward from the wheel. This will pop the wheel cover retaining tabs over the two remaining wheel nuts, removing the wheel cover from the wheel. INSTALLATION NOTE: Wheel mounting nuts must be installed on the studs as shown to allow installation of the wheel cover (Fig. 37). 1. Place the wheel cover on the wheel in the following fashion: a. Align the valve notch in the wheel cover with the valve stem on the wheel. b. At the same time, align the two holes in the wheel cover having the retaining tabs with the two installed wheel nuts (Fig. 38). c. Press in on center of wheel cover until wheel cover retaining tabs push past and engage rear of previously installed wheel mounting nuts (Fig. 38). This will hold the wheel cover in place. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Cover > Component Information > Description and Operation > Page 2044 2. Install and lightly tighten the three remaining wheel mounting nuts, securing the wheel cover in place (Fig. 36). 3. Tighten all five wheel mounting nuts in the proper sequence (Fig. 39). Tighten wheel nuts to a torque of 135 Nm (100 ft. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub And Bearing Axle Hub Nut Front .................................................................................................................................................... ............................................. 244 Nm (180 ft. lbs.) Rear ..................................................................... ............................................................................................................................. 244 Nm (180 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Mounting (Lug) Nut ................................................................................................................... ............................................... 135 Nm (100 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front WHEEL MOUNTING STUDS FRONT REMOVAL CAUTION: Wheel mounting studs MUST NOT be hammered out of hub flange of hub and bearing assembly. If a stud is removed by hammering it out, damage to hub and bearing assembly will occur leading to premature bearing failure. 1. Raise vehicle. 2. Remove front wheel and tire assembly. 3. Remove two adapter mounting bolts securing disc brake caliper adapter to steering knuckle (Fig. 40). 4. Remove disc brake caliper and adapter as assembly from steering knuckle (Fig. 40). Hang assembly out of way using wire or a bungle cord. Use care not to overextend brake hose when doing this. 5. Remove brake rotor from hub by pulling it straight off wheel mounting studs (Fig. 40). 6. On wheel mounting stud to be removed, install a wheel mounting (lug) nut far enough so the threads on the stud are even with end of nut. Install Remover, Special Tool C-4150A, on hub and bearing flange and wheel stud (Fig. 41). 7. Tighten down on Remover, pushing wheel stud out of hub flange. Once shoulder of wheel stud is past flange, remove special tool. Remove nut Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2054 from stud and remove stud from hub flange. INSTALLATION 1. Install replacement wheel stud into flange of hub and bearing from rear. Install washers on wheel stud, then install a standard type wheel mounting (lug) nut on stud with flat side of lug nut against washers as shown (Fig. 42). 2. Tighten nut, pulling wheel stud into hub flange. Once head of stud is fully seated against rear of hub flange, remove nut and washers from stud. 3. Install brake rotor back on hub and bearing (Fig. 40). 4. Install brake caliper and adapter back over brake rotor aligning adapter with mounting holes on steering knuckle (Fig. 40). 5. Install two adapter mounting bolts securing adapter to steering knuckle. Tighten mounting bolts to 169 Nm (125 ft. lbs.)torque. 6. Install wheel and tire assembly. Tighten wheel mounting (lug) nuts in proper sequence to 135 Nm (100 ft. lbs.) torque. 7. Lower vehicle. 8. Road test vehicle to ensure proper operation of the brakes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2055 Wheel Fastener: Service and Repair Wheel Mounting Studs - Rear Removal REMOVAL CAUTION: If a wheel stud needs to be replaced in the hub and bearing assembly, the studs MUST NOT be hammered out of the hub flange. If a wheel stud is removed by hammering it out of the hub flange, damage to the hub and bearing assembly will occur leading to premature hub and bearing failure. NOTE: Use one of the following procedures to remove one of five studs on a hub and bearing flange. DISC BRAKES 1. Raise and support the vehicle. 2. Remove the rear wheel and tire assembly. 3. Remove the disc brake caliper to adapter guide pin bolts (Figure 1). Figure 1 Caliper Guide Pin Bolts 4. Remove the rear brake caliper from the adapter using the following procedure (Figure 2): a. Rotate the front of the caliper up from the adapter. b. Pull the rear of the caliper and the outboard brake shoe anti-rattle clip out from under the rear abutment on the brake adapter. c. Lift the caliper from the rotor and support it using a bungee cord or wire attached to the underbody of the vehicle. DO NOT allow the caliper to hang by the flex hose. Damage can result. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2056 Figure 2 Removing/Installing Caliper 5. Remove any brake rotor retainer clips, then remove the brake rotor by pulling it straight off the wheel studs. 6. Remove the hold-down spring and pin from the trailing parking brake shoe (Figure 3). Figure 3 Parking Brake Adjuster And Springs Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2057 7. Shorten (back off) the adjuster screw (Figure 3) to minimum length, then spread the leading and trailing parking brake shoes apart and remove the adjuster. 8. Remove the lower return spring from the leading and trailing parking brake shoes (Figure 3). 9. Pull the bottom of the trailing parking brake shoe rearward and retain it on the backing plate flange of the brake adapter (Figure 4). Figure 4 Puller C-4150A On Wheel Stud 10. Install Remover, Special Tool C-4150A, on the hub and bearing flange and wheel stud (Figure 4). 11. Tighten the Remover, pushing the wheel mounting stud out the rear of the hub and bearing flange. When the shoulder of the stud is past the flange, remove the Remover. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2058 Figure 5 Stud Removal/Installation 12. Rotate the hub and bearing flange around until the stud lines up with the pocket in the brake adapter, then remove the stud from the hub and bearing flange utilizing the extra clearance that pocket allows (Figure 5). DRUM BRAKES 1. Raise and support the vehicle. 2. Remove the rear wheel and tire assembly. See: Service and Repair 3. Remove the brake drum. 4. If possible, install a wheel mounting nut on the wheel stud to be removed so the threads on wheel stud are even with end of lug nut (Figure 6). Figure 6 Wheel Stud Removal From Hub And Bearing Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2059 5. Install Remover, Special Tool C-4150A, on the hub and bearing flange and wheel stud (Figure 6). 6. Tighten the Remover, pushing the wheel stud out the rear of the hub and bearing flange. When the shoulder of the wheel stud is past the flange, remove the Remover. 7. Remove the wheel stud from the hub and bearing flange. Installation INSTALLATION NOTE: Use one of the following procedures to install one of five studs on a hub and bearing flange. DISC BRAKES 1. Rotate the hub and bearing flange around until the stud mounting hole lines up with the pocket in the brake adapter. 2. Insert the NEW wheel stud into the hub and bearing flange from the rear utilizing the pocket in the brake adapter (Figure 4). 3. Install several washers and a standard wheel mounting (lug) nut on the wheel stud (Figure 1). Install the nut so that the flat side of the nut is against the washers to eliminate any binding. Figure 1 Wheel Mounting Stud Installation 4. Tighten the wheel mounting nut (Figure 1) pulling the wheel stud into the hub flange. When the head of the stud is fully seated against the rear of the hub flange, remove the nut and washers. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2060 5. Place the trailing parking brake shoe back into mounted position. 6. Install the lower return spring between the leading and trailing parking brake shoes (Figure 3). When installing the lower return spring, be sure to install it behind the parking brake shoes as shown. 7. Install the adjuster between the leading and trailing parking brake shoes (Figure 3). 8. Install the hold-down spring and pin through the trailing parking brake shoe (Figure 3). 9. Adjust the parking brake shoes. 10. Install the brake rotor on the hub and bearing. CAUTION: Use care when installing the brake caliper assembly onto the adapter, so the caliper guide pin bushings do not get damaged by the mounting bosses on the adapter. 11. Carefully lower the brake caliper with brake shoes over the brake rotor and onto the adapter using the reverse order of how it was removed (Figure 2). CAUTION: When installing the guide pin bolts, extreme caution should be taken not to cross-thread the caliper guide pin bolts. 12. Install the caliper guide pin bolts. Tighten the guide pin bolts to 35 Nm (26 ft. lbs.). 13. Install wheel and tire assembly on vehicle. Tighten the wheel mounting (lug) nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 14. Check operation of the parking brakes. 15. Lower the vehicle. DRUM BRAKES 1. Install the NEW wheel stud into the flange of the hub and bearing assembly. 2. Install several washers on the wheel stud (Figure 1), then install a wheel mounting (lug) nut on the stud with the flat side of the lug nut against the washers to eliminate any binding. 3. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing assembly. When the head of the stud is fully seated against the flange, remove the nut and washers. 4. Install the brake drum and adjust the brake shoes as necessary. 5. Install wheel and tire assembly on vehicle. Tighten the wheel mounting (lug) nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 6. Lower the vehicle. Figure 2 Removing/Installing Caliper Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2061 Figure 3 Parking Brake Adjuster And Springs Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2062 Figure 4 Stud Removal/Installation Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Cylinder Compression Pressure Cylinder Compression Pressure Minimum Compression Pressure 100 psi Maximum Variation Between Cylinders 25 % Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2068 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Remove the Auto Shutdown (ASD) relay from the PDC. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gauge adaptor Special Tool 8116 or the equivalent, into the # 1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer (Special Tool CH7059) with cable adaptors to the DRBIII. 7. Crank engine until maximum pressure is reached on gauge. Record this pressure as # 1 cylinder pressure. 8. Repeat the previous step for all remaining cylinders. 9. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 10. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 11. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Camshaft Bearing Diameter #1 ......................................................................................................................................................... .......... 50.800-50.825 mm (1.9999-2.0009 in.) #2 ............................................................................... .................................................................................... 50.393-50.419 mm (1.9839-1.9849 in.) #3 ..... .............................................................................................................................................................. 50.013-50.038 mm (1.9690-1.9699 in.) #4 .......................................................................................... ........................................................................... 49.606-49.632 mm (1.9529-1.954 in.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Torque Torque Camshaft Sprocket Bolt 40 ft.lb Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Thrust Plate > Component Information > Specifications Camshaft Thrust Plate: Specifications Camshaft Thrust Plate Bolts ................................................................................................................ .................................................. 12 Nm (105 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Camshaft Journal Diameter #1 ......................................................................................................................................................... .............. 50.724-50.775 mm (1.997-1.999 in.) #2 ............................................................................... .................................................................................... 50.317-50.368 mm (1.9809-1.9829 in.) #3 ..... .............................................................................................................................................................. 49.936-49.987 mm (1.9659-1.9679 in.) #4 .......................................................................................... ......................................................................... 49.530-49.581 mm (1.9499-1.9520 in.) Bearing Clearance Diametrical ..................................................................................................................................... 0.025-0.101mm (0.001-0.004 in.) Bearing Clearance (Max.Allowable) ................................................................................................................................................ 0.127 mm (0.005 in.) End Play ...................................................................................................................... ................................................. 0.254-0.508 mm (0.010-0.020 in.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2082 Camshaft: Description and Operation DESCRIPTION Fig.47 Fig.48 The nodular iron camshaft is mounted in the engine block and supported with four steel backed aluminum bearings (Fig. 47). A thrust plate, located in front of the first bearing, is bolted to the block and controls the camshaft end play (Fig. 47). To distinguish camshafts between the 3.3L and 3.8L engines, a cast-in ring is located between the rear bearing journal and rear lobe (Fig. 48). The 3.3L engine application is as-cast only. The 3.8L engine application the cast ring is machined off. OPERATION The camshaft is driven by the crankshaft through a timing chain and sprockets. The camshaft has precisely machined (egg-shaped) lobes to provide accurate valve timing and duration. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2083 Camshaft: Service and Repair REMOVAL 1. Remove the engine assembly from vehicle. Remove the cylinder heads. 2. Remove the timing chain and camshaft sprocket. 3. Remove the hydraulic lifters. Identify each tappet for reinstallation in original location. Fig.47 4. Remove camshaft thrust plate (Fig. 47). 5. Install a long bolt into front of camshaft to facilitate removal of the camshaft. 6. Remove the camshaft (Fig. 47), being careful not to damage cam bearings with the cam lobes. NOTE: The camshaft bearings are serviced with the engine block. INSPECTION Fig.49 1. Check the cam lobes and bearing surfaces for abnormal wear and damage (Fig. 49). Replace camshaft as required. NOTE: If camshaft is replaced due to lobe wear or damage, always replace the lifters. 2. Measure the lobe actual wear (unworn area - wear zone = actual wear) (Fig. 49) and replace camshaft if out of limit. Standard value .................................................................................................................................... ..................................... 0.0254 mm (0.001 in.) Wear limit .................................................................. ............................................................................................................... 0.254 mm (0.010 in.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2084 INSTALLATION 1. Lubricate camshaft lobes and camshaft bearing journals with engine oil. 2. Install a long bolt into the camshaft to assist in the installation of the camshaft. 3. Carefully install the camshaft in engine block. 4. Install camshaft thrust plate and bolts (Fig. 47). Tighten to 12 Nm (105 in. lbs.) torque. 5. Measure camshaft end play. If not within specifications, replace thrust plate. 6. Install the timing chain and sprockets. NOTE: When camshaft is replaced, all of the hydraulic lifters must be replaced also. 7. Install the hydraulic lifters. Each lifter reused must be installed in the same position from which it was removed. 8. Install the timing chain cover. 9. Install the cylinder heads. 10. Install the cylinder head covers. 11. Install the lower and upper intake manifolds. 12. Install the engine assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Type ..................................................................................................................................................... ..................................................... Hydraulic Roller Diameter O.D. ......................................................................................................................................................... 22.949 - 22.962 mm (0.903 - 0.904 in.) Clearance In Block .................................................................................................................................................. 0.020 - 0.061 mm (0.0007 - 0.0024 in.) Lifter Yoke Retainer Bolts .................................................................................................................... ................................................ 12 Nm (105 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 2088 Lifter / Lash Adjuster: Description and Operation DESCRIPTION The hydraulic lifters are a roller type design and are positioned in the cylinder block. The lifters are aligned and retained by a yoke and a retainer (Fig. 71). Lifter alignment is maintained by machined flats on lifter body. Lifters are fitted in pairs into six aligning yokes. The aligning yokes are secured by a yoke retainer (Fig. 71). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 2089 Lifter / Lash Adjuster: Testing and Inspection HYDRAULIC LIFTERS DIAGNOSIS - PRELIMINARY STEP Before disassembling any part of the engine to correct lifter noise, check the engine oil pressure. Check engine oil level. The oil level in the pan should never be above the MAX mark on dipstick, or below the MIN mark. Either of these two conditions could cause noisy lifters. OIL LEVEL TOO HIGH If oil level is above the MAX mark on dipstick, it is possible for the connecting rods to dip into the oil while engine is running and create foaming. Foam in oil pan would be fed to the hydraulic lifters by the oil pump causing them to become soft and allow valves to seat noisily. OIL LEVEL TOO LOW Low oil level may allow pump to take in air which when fed to the lifters it causes them to become soft and allows valves to seat noisily. Any leaks on intake side of pump, through which air can be drawn, will create the same lifter noise. Check the lubrication system from the intake strainer to the oil pump cover, including the relief valve retainer cap. When lifter noise is due to aeration, it may be intermittent or constant, and usually more than one lifter will be noisy. When oil level and leaks have been corrected, the engine should be operated at fast idle to allow all of the air inside of the lifters to be bled out. VALVE TRAIN NOISE To determine source of valve train noise, operate engine at idle with cylinder head covers removed and listen for source of the noise. NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy lifters. If such is the case, noise may be dampened by applying side thrust on the valve spring. If noise is not appreciably reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm push rod sockets and push rod ends for wear. Valve lifter noise ranges from light noise to a heavy click. A light noise is usually caused by excessive leak-down around the unit plunger, which will necessitate replacing the lifter, or by the plunger partially sticking in the lifter body cylinder. A heavy click is caused either by a lifter check valve not seating, or by foreign particles becoming wedged between the plunger and the lifter body causing the plunger to stick in the down position. This heavy click will be accompanied by excessive clearance between the valve stem and rocker arm as valve closes. In either case, lifter assembly should be removed for inspection. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 2090 Lifter / Lash Adjuster: Service and Repair REMOVAL 1. Remove the cylinder head(s). 2. Remove the yoke retainer and aligning yokes (Fig. 73). 3. Remove the hydraulic lifters. If necessary use Special Tool C-4129, or equivalent to remove lifters from bores. If lifters are to be reused, identify each lifter to ensure installation in original location. INSTALLATION 1. Lubricate the lifters with engine oil. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 2091 NOTE: Position the lifter in bore with the lubrication hole facing upward (Fig. 72). 2. Install the hydraulic lifters with the lubrication hole facing upward towards middle of block (Fig. 72). Install lifters in original positions, if reused. 3. Install lifter aligning yokes (Fig. 73). 4. Install yoke retainer and torque screws to 12 Nm (105 in. lbs.) (Fig. 73). 5. Install the cylinder heads. 6. Start and operate engine. Warm up to normal operating temperature. CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic lifters have filled with oil and have become quiet. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Specifications Push Rod: Specifications Push Rod Length ................................................................................................................................. ............................................... 135.438 mm (5.33 in.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Specifications > Page 2095 Push Rod: Description and Operation DESCRIPTION - PUSHRODS The pushrods are made of steel and are a hollow design. The pushrods are positioned between the hydraulic lifter and the rocker arm. OPERATION - PUSHRODS The pushrod is a solid link between the hydraulic lifter and the rocker arm. Also, the pushrod supplies engine oil from the hydraulic lifter to the rocker arm. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Shaft Bolts ....................................................................................................................... ................................................. 23 Nm (200 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 2099 Rocker Arm Assembly: Description and Operation ROCKER ARMS DESCRIPTION - ROCKER ARMS The rocker arms are installed on the rocker arm shaft. The rocker arms and shaft assembly is attached to the cylinder head with seven billeted bolts and retainers. The rocker arms are made of stamped steel. OPERATION - ROCKER ARMS The rocker arm pivots on the rocker shaft. Rocker arms are used to translate up and down motions provided by the camshaft, hydraulic lifter, and pushrod on one end, into a down and up motions on the valve stem on the opposing end. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 2100 Rocker Arm Assembly: Service and Repair REMOVAL - ROCKER ARMS AND SHAFT 1. Remove the cylinder head cover(s). (Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL) NOTE: Rocker arm shaft bolts are captured to the shaft. 2. Loosen the rocker shaft bolts (Fig. 24), rotating one turn each, until all valve spring pressure is relieved. 3. Remove the rocker arms and shaft assembly (Fig. 24). 4. For rocker arm disassembly procedures, (Refer to - ENGINE/CYLINDER HEAD/ROCKER ARMS DISASSEMBLY). DISASSEMBLY - ROCKER ARMS AND SHAFT CAUTION: Do not attempt to drive the billeted bolt from the rocker shaft. This can damage the rocker arm retainer and bolt assembly. 1. Remove the rocker arm retainer and bolt by performing the following procedure: a. Using adjustable pliers, grip the edges of the retainer (Fig. 25). b. Apply an upward force with a slight rocking motion until the retainer disengages from shaft (Fig. 25). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 2101 2. Remove rocker arms (Fig. 26). Identify the component locations for reassembly in original locations. ASSEMBLY - ROCKER ARMS AND SHAFT 1. Install rocker arms on the shaft (Fig. 26). Install in the original positions if re-used. Ensure the rocker shaft, all the retainers and washers are properly positioned and installed in the correct locations (Fig. 26). 2. Install rocker arms and shaft to the cylinder head. (Refer to - ENGINE/CYLINDER HEAD/ ROCKER ARMS INSTALLATION) INSTALLATION ROCKER ARMS AND SHAFT CAUTION: Ensure the longer shaft retaining bolt is installed in the proper location on the rocker shaft. (Refer to - ENGINE/CYLINDER HEAD/ROCKER ARMS - ASSEMBLY) 1. Position the rocker arm and shaft assemblies on the pedestal mounts. CAUTION: Ensure all pushrods are properly located on the lifter and the rocker arm socket. 2. Align each rocker arm socket with each pushrod end. CAUTION: The rocker arm shaft should be tightened down slowly, starting with the center bolts. Allow 20 minutes lifter bleed down time after installation of the rocker shafts before engine operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 2102 3. Slowly tighten rocker shaft bolts evenly until shaft is seated. Tighten bolts to 23 Nm (200 inch lbs.) (Fig. 27). 4. Install the cylinder head cover(s). (Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications CONNECTING RODS Bearing Clearance ............................................................................................................................................................ 0.019-0.065 (0.017-0.020 in.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 2107 Connecting Rod Bearing: Service and Repair MEASURING CONNECTING ROD BEARING CLEARANCE The bearing caps are not interchangeable and should be marked at removal to ensure correct assembly. The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps. Install cap with the tangs on the same side as the rod. Fit all rods on one bank until complete. Connecting rod bearings are available in the standard size and the following undersizes: 0.025 mm (0.001 in.) and 0.250 mm (0.010 in.). CAUTION: Install the bearings in pairs. Do not use a new bearing half with an old bearing half. Do not file the rods or bearing caps. Measure connecting rod journal for taper and out-of-round. The connecting rod bearing clearances can be determined by use of Plastigage or the equivalent. The following is the recommended procedure for the use of Plastigage: 1. Rotate the crankshaft until the connecting rod to be checked is at the bottom of its stroke. 2. Remove oil film from surface to be checked. Plastigage is soluble in oil. 3. Place a piece of Plastigage across the entire width of the bearing shell in the bearing cap approximately 6.35 mm (1/4 in.) off center and away from the oil hole. In addition, suspect areas can be checked by placing Plastigage in that area. 4. Assemble the rod cap with Plastigage in place. Tighten the rod cap to the specified torque. Do not rotate the crankshaft while assembling the cap or the Plastigage may be smeared, giving inaccurate results. Fig.50 5. Remove the bearing cap and compare the width of the flattened Plastigage with the scale provided on the package (Fig. 50). Locate the band closest to the same width. This band indicates the amount of oil clearance. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Refer to Specifications. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. If the bearing clearance exceeds wear limit specification, replace the bearing. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Connecting Rod: Specifications Connecting Rod CONNECTING RODS Bearing Clearance ............................................................................................................................................................ 0.019-0.065 (0.017-0.020 in.) Wear Limit ........................................................................................................................................... ...................................... 0.074 mm (0.003 in.) Side Clearance .................................................................................................................................... ............................. 0.13-0.32 mm (0.005-0.013 in.) Wear Limit ........................................................................................................................................... ........................................ 0.38 mm (0.015 in.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod > Page 2112 Connecting Rod: Specifications Connecting Rod Bolt/Nut Connecting Rod Cap Bolts ..................................................................................................................................................... 54 Nm (40 ft. lbs.) + 1/4 turn Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 2113 Connecting Rod: Description and Operation PISTON & CONNECTING ROD DESCRIPTION The pistons are made of cast aluminum alloy and are a strutless, short skirt design. The piston rings consist of two compression rings and a three piece oil ring. Piston pins connect the piston to the forged steel connecting rods. The piston pins are a press fit into the connecting rod. OPERATION The piston and connecting rod is the link between the combustion force to the crankshaft. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures Connecting Rod: Procedures FITTING CONNECTING RODS The bearing caps are not interchangeable or reversible, and should be marked at removal to ensure correct reassembly. The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps. Install cap with the tangs on the same side as the rod. For connecting rod bearing fitting. Fit all connecting rods on one bank until complete. Fig.74 NOTE: The connecting rod cap bolts should be examined before reuse. Bolt stretch can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt must be replaced (Fig. 74). 1. Before installing the nuts the threads should be oiled with engine oil. 2. Install nuts finger tight on each bolt then alternately torque each nut to assemble the cap properly. 3. Tighten the nuts to 54 Nm PLUS 1/4 turn (40 ft. lbs. PLUS 1/4 turn). Fig.75 4. Using a feeler gauge, check connecting rod side clearance (Fig. 75). Refer to Specifications. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 2116 Connecting Rod: Removal and Replacement PISTON & CONNECTING ROD REMOVAL 1. Disconnect negative cable from battery. 2. Remove the cylinder heads. 3. Remove the oil pan. 4. Remove the top ridge of cylinder bores with a reliable ridge reamer, if necessary, before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so that each connecting rod is centered in cylinder bore. Fig.78 5. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them, if necessary (Fig. 78). Fig.79 6. Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts (Fig. 79). 7. Remove each piston and connecting rod assembly out of the cylinder bore. NOTE: Be careful not to nick crankshaft journals. 8. After removal, install bearing cap on the mating rod. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 2117 Fig.80 1. Before installing pistons and connecting rod assemblies into the bore, ensure that compression ring gaps are staggered so that neither is in line with oil ring rail gap (Fig. 80). 2. Before installing the ring compressor, ensure the oil ring expander ends are butted and the rail gaps located as shown in (Fig. 80). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 2118 Fig.81 3. Lubricate the piston and rings with clean engine oil. Position a ring compressor over the piston and rings, and tighten the compressor (Fig. 81). Be sure position of rings does not change during this operation. 4. Position upper bearing onto connecting rod. Lubricate bearing with oil. 5. Install connecting rod bolt protectors (rubber hose or equivalent) on the connecting rod bolts (Fig. 81). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 2119 Fig.82 6. The pistons are marked with a "F" located near the piston pin. Install piston with this mark positioned to front of engine on both cylinder banks. The connecting rod oil squirt hole faces the major thrust (right) side of the engine block (Fig. 82). 7. Rotate crankshaft until the connecting rod journal is located in the center of the cylinder bore. Insert connecting rod and piston into cylinder bore. Carefully guide connecting rod over the crankshaft journal (Fig. 81). 8. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. 9. Install lower bearing shell and connecting rod cap (Fig. 81). Install nuts on cleaned and oiled rod bolts and tighten to 54 Nm (40 ft. lbs.) PLUS 1/4 turn. 10. Repeat procedure for each piston and connecting rod installation. 11. Install the cylinder heads. 12. Install the oil pan. 13. Fill engine crankcase with proper oil to correct level. 14. Connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications Cylinder Block Drain Plugs .................................................................................................................. .................................................. 20 Nm (15 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications "Information not supplied by the manufacturer" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications > Page 2126 Crankshaft Gear/Sprocket: Service and Repair "For information regarding this component please refer to Timing chain service and repair" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Service Specifications Crankshaft Main Bearing: Specifications Material Nodular Iron Connecting Rod Journal Diameter 2.2827 - 2.2837 in Main Bearing Journal Diameter 2.5194 - 2.5202 in Out-of-Round (Max.) 0.001 in Taper (Max.) 0.001 in End Play Standard 0.0036 - 0.0095 in Wear Limit 0.015 in Main Bearing Diametrical Clearance No. 1, 2, 3, 4 0.0005 - 0.0022 in Wear Limit 0.003 in Main Bearing Cap Bolts 30 ft.lb + 1/4 turn Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > Service Specifications > Page 2131 Crankshaft Main Bearing: Specifications Torque Specifications 1. Tighten # 1, 3 and 4 main cap bolts to 41 Nm (30 ft. lbs.) + 1/4 Turn. 2. Rotate the crankshaft until the number 6 piston is at TDC. 3. To ensure correct thrust bearing alignment, the following procedure must be done: - Move crankshaft all the way to the rear of its travel. - Then, move crankshaft all the way to the front of its travel. - Wedge an appropriate tool between the rear of the cylinder block and rear crankshaft counterweight. This will hold the crankshaft in it's most forward position. - Tighten the # 2 thrust bearing cap bolts to 41 Nm + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). Remove the holding tool. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Procedures Crankshaft Main Bearing: Procedures MAIN BEARING FITTING Fig.58 Bearing caps are not interchangeable and should be marked at removal to insure correct assembly (Fig. 58). Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves of 1, 3 and 4 are interchangeable. Upper main bearing halves of 1, 3 and 4 are interchangeable. Fig.59 Upper and lower number 2 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine (Fig. 59). All bearing cap bolts removed during service procedures are to be cleaned and lubricated with engine oil before installation. Bearing shells are available in standard and the following undersizes: 0.025 mm (0.001 in.) and 0.254 mm (0.010 in.). Never install an undersize bearing that will reduce clearance below specifications. CRANKSHAFT BEARING OIL CLEARANCE Inspect the crankshaft bearing journals. Engine crankshaft bearing clearances can be determined by use of Plastigage or the equivalent. The following is the recommended procedures for the use of Plastigage with the engine in the vehicle or engine on a repair stand. PLASTIGAGE METHOD-ENGINE IN-VEHICLE NOTE: The total clearance of the main bearings can only be determined with the engine in the vehicle by removing the weight of the crankshaft. This can be accomplished by either of two following methods: 1. Preferred method: a. Shim the bearings adjacent to the bearing to be checked in order to remove the clearance between upper bearing shell and the crankshaft. This Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Procedures > Page 2134 can be accomplished by placing a minimum of 0.254 mm (0.010 in.) shim (e. g. cardboard, matchbook cover, etc.) between the bearing shell and the bearing cap on the adjacent bearings and tightening bolts to 14 - 20 Nm (10 - 15 ft. lbs.). When checking # 1 main bearing shim # 2 main bearing. - When checking # 2 main bearing shim # 1 & # 3 main bearing. - When checking # 3 main bearing shim # 2 & # 4 main bearing. - When checking # 4 main bearing shim # 3 main bearing. NOTE: Remove all shims before reassembling engine. 2. Alternative Method: a. Support the weight of the crankshaft with a jack under the counterweight adjacent to the bearing being checked. 3. Remove oil film from surface to be checked. Plastigage is soluble in oil. Fig.60 4. Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately 6.35 mm (1/4 in.) off center and away from the oil holes (Fig. 60). and addition, suspected areas can be checked by placing the Plastigage in the suspected area). Torque the bearing cap bolts of the bearing being checked to the proper specifications. Fig.61 5. Remove the bearing cap and compare the width of the flattened Plastigage (Fig. 61) with the scale provided on the package. Locate the band closest to the same width. This band shows the amount of clearance in thousandths. Differences in readings between the ends indicate the amount of taper present. Record all readings taken. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a metric scale. NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for the specifications you are checking. PLASTIGAGE METHOD-ENGINE OUT-OF-VEHICLE 1. With engine in the inverted position (crankshaft up) and mounted on a repair stand, remove main journal cap. 2. Remove oil from journal and bearing shell. 3. Cut Plastigage to same length as width of the bearing and place it in parallel with the journal axis (Fig. 60). 4. Carefully install the main bearing cap and tighten the bolts to specified torque. CAUTION: Do not rotate crankshaft or the Plastigage will be smeared. 5. Carefully remove the bearing cap and measure the width of the Plastigage at the widest part using the scale on the Plastigage package (Fig. 61). If the clearance exceeds the specified limits, replace the main bearing(s) with the appropriate size, and if necessary, have the crankshaft machined to Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Procedures > Page 2135 next undersize. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Procedures > Page 2136 Crankshaft Main Bearing: Removal and Replacement REMOVAL - CRANKSHAFT MAIN BEARINGS 1. Remove the oil pan. 2. Identify main bearing caps before removal. Fig.62 3. Remove bearing caps one at a time. Remove upper half of bearing by inserting Special Main Bearing Tool C-3059 (Fig. 62) into the oil hole of crankshaft. 4. Slowly rotate crankshaft clockwise, forcing out upper half of bearing shell. INSTALLATION - CRANKSHAFT MAIN BEARINGS NOTE: One main bearing should be selectively fitted while all other main bearing caps are properly tightened. 1. For main bearing fitting procedure, Refer to CRANKSHAFT MAIN BEARINGS - STANDARD PROCEDURE 2. Start bearing in place, and insert Main Bearing Tool C-3059 into oil hole of crankshaft (Fig. 62). 3. Slowly rotate crankshaft counterclockwise sliding the bearing into position. Remove Special Main Bearing Tool C-3059. Fig.63 4. Inspect main cap bolts for stretching (Fig. 63). Replace bolts that are stretched. NOTE: The main cap bolts should be examined before reuse. Bolt stretch can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt must be replaced (Fig. 63). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Procedures > Page 2137 5. Install each main cap and tighten bolts finger tight. 6. Tighten number 1, 3 and 4 main cap bolts to 41 Nm (30 ft. lbs.) + 1/4 turn. 7. Rotate the crankshaft until the number 6 piston is at TDC. 8. To ensure correct thrust bearing alignment the following procedure must be done: a. Move crankshaft all the way to the rear of its travel. b. Then, move crankshaft all the way to the front of its travel. c. Wedge an appropriate tool between the rear of the cylinder block and rear crankshaft counterweight. This will hold the crankshaft in its most forward position. d. Tighten the # 2 thrust bearing cap bolts to 41 Nm (30 ft. lbs.) + 1/4 turn. Remove the holding tool. 9. Install oil pan. 10. Fill engine crankcase with proper oil to correct level. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Specifications Crankshaft Seal Retainer: Specifications Rear Seal Retainer Bolts 105 in.lb Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Specifications > Page 2141 Crankshaft Seal Retainer: Service and Repair REMOVAL 1. Remove crankshaft rear oil seal. 2. Remove oil pan. Fig.69 3. Remove oil seal retainer screws (Fig. 69). 4. Remove oil seal retainer (Fig. 69). 5. Clean engine block and retainer of oil and gasket material. Make sure surfaces are clean and free of oil. INSTALLATION 1. Position new gasket and install retainer on block (Fig. 69). Tighten attaching screws to 12 Nm (105 in. lbs.). 2. Install oil pan. 3. Install oil seal. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Material Nodular Iron Connecting Rod Journal Diameter 2.2827 - 2.2837 in Main Bearing Journal Diameter 2.5194 - 2.5202 in Out-of-Round (Max.) 0.001 in Taper (Max.) 0.001 in End Play Standard 0.0036 - 0.0095 in Wear Limit 0.015 in Main Bearing Diametrical Clearance No. 1, 2, 3, 4 0.0005 - 0.0022 in Wear Limit 0.003 in Main Bearing Cap Bolts 30 ft.lb + 1/4 turn Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 2145 Crankshaft: Description and Operation DESCRIPTION Fig.51 The nodular iron crankshaft is supported by four main bearings, with number two position the thrust bearing (Fig. 51). Crankshaft end sealing is provided by front and rear rubber seals. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures Crankshaft: Procedures MEASURING CRANKSHAFT END PLAY Fig.53 1. Mount a dial indicator to front of engine with the locating probe on nose of crankshaft (Fig. 53). 2. Move crankshaft all the way to the rear of its travel. 3. Zero the dial indicator. 4. Move crankshaft all the way to the front and read the dial indicator. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 2148 Crankshaft: Removal and Replacement REMOVAL 1. Remove the engine assembly. 2. Separate transaxle from engine. 3. Mount engine on an engine stand. 4. Remove the oil filter. 5. Remove the oil pan and oil pick-up tube. 6. Remove the timing chain cover. 7. Remove timing chain and sprockets. 8. Remove crankshaft rear oil seal and retainer. 9. Rotate the crankshaft until connecting rod cap is accessible. 10. Mark connecting rod cap position using a suitable marker/scribe tool. 11. Remove connecting rod bearing cap. Use care to prevent damage to the crankshaft bearing surfaces. 12. Repeat removal procedure for each connecting rod cap. 13. Remove and discard the main bearing cross bolts and washers (3.8L engine only). NOTE: Install new cross bolt and washer assembly (3.8L engine only) upon reassembly. 14. Remove the main bearing cap bolts 15. Remove the main bearing caps. 16. Remove the crankshaft from engine block. INSPECTION Fig.54 The crankshaft journals should be checked for excessive wear, taper and scoring (Fig. 54). Limits of taper or out of round on any crankshaft journals should within specifications. Journal grinding should not exceed 0.305 mm (0.012 in.) under the standard journal diameter. DO NOT grind thrust faces of No. 3 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages. CAUTION: With the nodular cast iron crankshafts, it is important that the final paper or cloth polish be in the same direction as normal rotation in the engine. INSTALLATION 1. Lubricate with engine oil and install the crankshaft main bearing halves in the engine block. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 2149 Fig.56 2. Position the crankshaft in engine block (Fig. 56). 3. Perform main bearing fitting procedure. Fig.55 4. Inspect main cap bolts for stretching (Fig. 55). Replace bolts that are stretched. NOTE: The main cap bolts should be examined before reuse. Bolt stretch can be checked by holding a scale or straight edge against the threads. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Procedures > Page 2150 If all the threads do not contact the scale the bolt must be replaced (Fig. 55). 5. Install the main bearing caps and bolts. Tighten bolts to 41 Nm (30 ft. lbs.) plus 1/4 turn. NOTE: Install new cross bolt and washer assembly (3.8L engine only) upon reassembly. Fig.57 6. Install and tighten the NEW cross bolts and washer assemblies (3.8L engine only) to 61 Nm (45 ft. lbs.) (Fig. 57). 7. Position and install the connecting rod and bearing caps on the crankshaft. 8. Install the crankshaft rear oil seal. 9. Install the crankshaft sprocket. 10. Install the timing chain and camshaft sprocket. 11. Install the timing chain cover. 12. Install the oil pick-up tube and oil pan. 13. Install the transaxle to the engine. 14. Install the engine assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation Engine Block Heater: Description and Operation DESCRIPTION The engine block heater is available as an optional accessory on all models. The heater is operated by ordinary house current (110 Volt A.C.) through a power cord located behind the radiator grille. This provides easier engine starting and faster warm-up when vehicle is operated in areas having extremely low temperatures. The heater is mounted in a core hole (in place of a core hole plug) in the engine block, with the heating element immersed in coolant. OPERATION The block heater element is submerged in the cooling system's coolant. When electrical power (110 volt A.C.) is applied to the element, it creates heat. This heat is transferred to the engine coolant. This provides easier engine starting and faster warm-up when vehicle is operated in areas having extremely low temperatures. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 2154 Engine Block Heater: Testing and Inspection ENGINE BLOCK HEATER TESTING If unit does not operate, trouble can be in either the power cord or the heater element. Test power cord for continuity with a 110-volt voltmeter or 110 volt test light; test heater element continuity with an ohmmeter or 12-volt test light. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 2155 Engine Block Heater: Service and Repair REMOVAL 1. Drain coolant from radiator and cylinder block. 2. Disconnect the power cord plug from heater. 3. Loosen screw in center of heater. Remove the heater assembly. INSTALLATION 1. Clean block core hole and heater seat. 2. Insert heater assembly with element loop positioned upward. 3. With heater seated, tighten center screw securely to assure a positive seal. 4. Install power cord plug to heater. 5. Fill cooling system with coolant to the proper level. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Torque Torque Crankshaft Damper Bolt 40 ft.lb Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2159 Harmonic Balancer - Crankshaft Pulley: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Raise vehicle on hoist. 3. Remove the right front wheel and inner splash shield. 4. Remove the accessory drive belt. 5. Remove vibration damper bolt. 6. Insert Special Tool 8450 into crankshaft nose (Fig. 89). 7. Position 3 jaw puller Special Tool 1026 on damper as shown in (Fig. 89). Turn puller, forcing screw until damper releases from crankshaft. 8. Remove the crankshaft vibration damper. INSTALLATION 1. Install crankshaft vibration damper using the forcing screw, nut, and thrust bearing/washer from Special Tool 8452 (Fig. 90). NOTE: To minimize friction and prolong tool life, lubricate the threads on the forcing screw of Special Tool 8452. 2. Position vibration damper on crankshaft. 3. Screw Special Tool 8452 into crankshaft until the bolt seats. Turn the nut to install damper until it seats fully. 4. Remove Special Tool 8452. 5. Install vibration damper bolt. Torque bolt to 54 Nm (40 ft. lbs.). 6. Install the accessory drive belt. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2160 7. Install inner splash shield and right front wheel. 8. Connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Diameter 3.660 - 3.661 in Measured @1.567 in. from top of piston. Clearance in Bore @ Size Location -0.0002 - 0.0015 in Weight 12.77 ± 0.1764 oz (US) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 2164 Piston: Description and Operation PISTON & CONNECTING ROD DESCRIPTION The pistons are made of cast aluminum alloy and are a strutless, short skirt design. The piston rings consist of two compression rings and a three piece oil ring. Piston pins connect the piston to the forged steel connecting rods. The piston pins are a press fit into the connecting rod. OPERATION The piston and connecting rod is the link between the combustion force to the crankshaft. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures Fitting Connecting Rods FITTING CONNECTING RODS The bearing caps are not interchangeable or reversible, and should be marked at removal to ensure correct reassembly. The bearing shells must be installed with the tangs inserted into the machined grooves in the rods and caps. Install cap with the tangs on the same side as the rod. For connecting rod bearing fitting. Fit all connecting rods on one bank until complete. Fig.74 NOTE: The connecting rod cap bolts should be examined before reuse. Bolt stretch can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt must be replaced (Fig. 74). 1. Before installing the nuts the threads should be oiled with engine oil. 2. Install nuts finger tight on each bolt then alternately torque each nut to assemble the cap properly. 3. Tighten the nuts to 54 Nm PLUS 1/4 turn (40 ft. lbs. PLUS 1/4 turn). Fig.75 4. Using a feeler gauge, check connecting rod side clearance (Fig. 75). Refer to Specifications. Piston to Cylinder Bore Fitting FITTING PISTONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2167 The piston and cylinder wall must be clean and dry. Piston diameter should be measured 90 degrees to piston pin at size location shown in (Fig. 76). Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine crankshaft center line shown in (Fig. 77). Refer to Specifications. Pistons and cylinder bores should be measured at normal room temperature, 21 °C (70 °F). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2168 Piston: Removal and Replacement PISTON & CONNECTING ROD REMOVAL 1. Disconnect negative cable from battery. 2. Remove the cylinder heads. 3. Remove the oil pan. 4. Remove the top ridge of cylinder bores with a reliable ridge reamer, if necessary, before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so that each connecting rod is centered in cylinder bore. Fig.78 5. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them, if necessary (Fig. 78). Fig.79 6. Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts (Fig. 79). 7. Remove each piston and connecting rod assembly out of the cylinder bore. NOTE: Be careful not to nick crankshaft journals. 8. After removal, install bearing cap on the mating rod. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2169 Fig.80 1. Before installing pistons and connecting rod assemblies into the bore, ensure that compression ring gaps are staggered so that neither is in line with oil ring rail gap (Fig. 80). 2. Before installing the ring compressor, ensure the oil ring expander ends are butted and the rail gaps located as shown in (Fig. 80). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2170 Fig.81 3. Lubricate the piston and rings with clean engine oil. Position a ring compressor over the piston and rings, and tighten the compressor (Fig. 81). Be sure position of rings does not change during this operation. 4. Position upper bearing onto connecting rod. Lubricate bearing with oil. 5. Install connecting rod bolt protectors (rubber hose or equivalent) on the connecting rod bolts (Fig. 81). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2171 Fig.82 6. The pistons are marked with a "F" located near the piston pin. Install piston with this mark positioned to front of engine on both cylinder banks. The connecting rod oil squirt hole faces the major thrust (right) side of the engine block (Fig. 82). 7. Rotate crankshaft until the connecting rod journal is located in the center of the cylinder bore. Insert connecting rod and piston into cylinder bore. Carefully guide connecting rod over the crankshaft journal (Fig. 81). 8. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. 9. Install lower bearing shell and connecting rod cap (Fig. 81). Install nuts on cleaned and oiled rod bolts and tighten to 54 Nm (40 ft. lbs.) PLUS 1/4 turn. 10. Repeat procedure for each piston and connecting rod installation. 11. Install the cylinder heads. 12. Install the oil pan. 13. Fill engine crankcase with proper oil to correct level. 14. Connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Ring End Gap Top Compression Ring Standard 0.007 - 0.015 in Wear Limit 0.039 in 2nd Compression Ring Standard 0.011 - 0.022 in Wear Limit 0.039 in Oil Control Steel Rails Standard 0.009 - 0.030 in Wear Limit 0.074 in Ring Side Clearance Top Compression Ring Standard 0.0012 - 0.0031 in Wear Limit 0.004 in 2nd Compression Ring Standard 0.0012 - 0.0037 in Wear Limit 0.005 in Oil Control Steel Rails Standard 0.0015 - 0.0078 in Wear Limit 0.009 in Ring Width Compression Rings 0.0575 - 0.058 in Oil Control Steel Rails 0.017 - 0.019 in Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Piston Ring Fitting Piston Ring: Service and Repair Piston Ring Fitting PISTON RING FITTING Fig.83 1. Wipe cylinder bore clean. Insert the ring and push down with piston to ensure squareness in bore to approximately 12 mm (0.50 in.) from top of cylinder bore. Check ring gap with a feeler gauge (Fig. 83). Fig.84 2. Check piston ring to groove side clearance (Fig. 84). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Piston Ring Fitting > Page 2177 Piston Ring: Service and Repair Piston Ring - Removal and Installation REMOVAL 1. Remove piston and connecting rod. Fig.87 2. Remove No. 1 and No. 2 piston rings from piston using a ring expander tool (Fig. 87). Fig.86 3. Remove upper oil ring side rail (Fig. 86). 4. Remove lower oil ring side rail (Fig. 86). 5. Remove oil ring expander (Fig. 86). INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair > Piston Ring Fitting > Page 2178 Fig.85 1. Install rings with manufacturers I.D. mark (if present) facing up, to the top of the piston (Fig. 85). CAUTION: Install piston rings in the following order: a. Oil ring expander. b. Upper oil ring side rail. c. Lower oil ring side rail. d. No. 2 Intermediate piston ring. e. No. 1 Upper piston ring. 2. Install the side rail by placing one end between the piston ring groove and the expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander (Fig. 86). 3. Install upper side rail first and then the lower side rail. 4. Install No. 2 piston ring and then No. 1 piston ring (Fig. 87). Fig.88 5. Position piston ring end gaps as shown in (Fig. 88). 6. Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin center or on the thrust direction. Staggering ring gap is important for oil control. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm Shaft Bolts ....................................................................................................................... ................................................. 23 Nm (200 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 2186 Rocker Arm Assembly: Description and Operation ROCKER ARMS DESCRIPTION - ROCKER ARMS The rocker arms are installed on the rocker arm shaft. The rocker arms and shaft assembly is attached to the cylinder head with seven billeted bolts and retainers. The rocker arms are made of stamped steel. OPERATION - ROCKER ARMS The rocker arm pivots on the rocker shaft. Rocker arms are used to translate up and down motions provided by the camshaft, hydraulic lifter, and pushrod on one end, into a down and up motions on the valve stem on the opposing end. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 2187 Rocker Arm Assembly: Service and Repair REMOVAL - ROCKER ARMS AND SHAFT 1. Remove the cylinder head cover(s). (Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL) NOTE: Rocker arm shaft bolts are captured to the shaft. 2. Loosen the rocker shaft bolts (Fig. 24), rotating one turn each, until all valve spring pressure is relieved. 3. Remove the rocker arms and shaft assembly (Fig. 24). 4. For rocker arm disassembly procedures, (Refer to - ENGINE/CYLINDER HEAD/ROCKER ARMS DISASSEMBLY). DISASSEMBLY - ROCKER ARMS AND SHAFT CAUTION: Do not attempt to drive the billeted bolt from the rocker shaft. This can damage the rocker arm retainer and bolt assembly. 1. Remove the rocker arm retainer and bolt by performing the following procedure: a. Using adjustable pliers, grip the edges of the retainer (Fig. 25). b. Apply an upward force with a slight rocking motion until the retainer disengages from shaft (Fig. 25). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 2188 2. Remove rocker arms (Fig. 26). Identify the component locations for reassembly in original locations. ASSEMBLY - ROCKER ARMS AND SHAFT 1. Install rocker arms on the shaft (Fig. 26). Install in the original positions if re-used. Ensure the rocker shaft, all the retainers and washers are properly positioned and installed in the correct locations (Fig. 26). 2. Install rocker arms and shaft to the cylinder head. (Refer to - ENGINE/CYLINDER HEAD/ ROCKER ARMS INSTALLATION) INSTALLATION ROCKER ARMS AND SHAFT CAUTION: Ensure the longer shaft retaining bolt is installed in the proper location on the rocker shaft. (Refer to - ENGINE/CYLINDER HEAD/ROCKER ARMS - ASSEMBLY) 1. Position the rocker arm and shaft assemblies on the pedestal mounts. CAUTION: Ensure all pushrods are properly located on the lifter and the rocker arm socket. 2. Align each rocker arm socket with each pushrod end. CAUTION: The rocker arm shaft should be tightened down slowly, starting with the center bolts. Allow 20 minutes lifter bleed down time after installation of the rocker shafts before engine operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 2189 3. Slowly tighten rocker shaft bolts evenly until shaft is seated. Tighten bolts to 23 Nm (200 inch lbs.) (Fig. 27). 4. Install the cylinder head cover(s). (Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Description and Operation Valve Cover: Description and Operation CYLINDER HEAD COVER(S) DESCRIPTION The cylinder head covers are made of stamped steel. The covers are sealed with steel reinforced silicon rubber gaskets. The cylinder head cover uses rubber isolators at each fastener location (Fig. 7). NOTE: Due to the tight packaging near the cylinder head covers, which makes spill clean-up difficult, a spill during an engine oil change may be misinterpreted as an oil leak. When investigating an oil leak in the location of the cylinder head covers and intake manifold, follow the procedure found in Oil Leak Diagnosis Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Left Side Cover Valve Cover: Service and Repair Left Side Cover CYLINDER HEAD COVER-LEFT REMOVAL 1. Disconnect spark plug wires from spark plugs. 2. Disconnect crankcase vent hose from cylinder head cover. 3. Remove cylinder head cover bolts. 4. Remove cylinder head cover and gasket. INSTALLATION 1. Clean cylinder head and cover mating surfaces. Inspect cylinder head cover surface for flatness. Replace gasket as necessary. 2. Assemble gasket to cylinder cover by inserting the fasteners through each bolt hole on cover and gasket (Fig. 9). 3. Install the cylinder head cover and bolts (Fig. 10). 4. Tighten cylinder head cover bolts to 12 Nm (105 inch lbs.) (Fig. 10). 5. Connect crankcase vent hose. 6. Connect spark plug wires to spark plugs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Left Side Cover > Page 2195 Valve Cover: Service and Repair Right Side Cover CYLINDER HEAD COVER RIGHT REMOVAL 1. Disconnect negative cable from battery. 2. Remove the wiper module. (Refer to ELECTRICAL/WIPERS/WASHERS/WIPER MODULE REMOVAL) 3. Disconnect spark plug wires from plugs. 4. Disconnect PCV hose from cylinder head cover (Fig. 8). 5. Remove cylinder head cover bolts. 6. Remove cylinder head cover and gasket (Fig. 7). INSTALLATION 1. Clean cylinder head and cover mating surfaces. Inspect cylinder head cover surface for flatness. Replace gasket as necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Left Side Cover > Page 2196 2. Inspect seal on the cover bolt for wear or damage (Fig. 9). Replace bolt assembly as necessary. NOTE: The cylinder head cover bolts contain a torque limiter sleeve and a seal (Fig. 9). The seal and torque sleeve is replaced with the bolt. 3. Assemble gasket to cylinder cover by inserting the bolt assemblies through each bolt hole on the cover and gasket (Fig. 9). 4. Install cylinder head cover and bolts (Fig. 10). 5. Tighten cylinder head cover bolts to 12 Nm (105 inch lbs.) (Fig. 10). 6. Connect PCV hose to cylinder head cover. 7. Connect spark plug wires to spark plugs. 8. Install wiper module. (Refer to - ELECTRICAL/WIPERS/WASHERS/WIPER MODULE INSTALLATION) 9. Connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Guide Bore Diameter (Std.) .......................................................................................................................................... 6.975 7.00 mm (0.274 - 0.275 in.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Angle ................................................................................................................................................... .................................................................. 44.5 - 45 ° Valve Seat Runout (Service Limits) ................................................................................................................................................... 0.0762 mm (0.003 in.) Valve Seat Width Intake ................................................................................................................................................... ........................ 1.50 - 2.00 mm (0.057 - 0.078 in.) Exhaust ................................................................ ........................................................................................................ 1.50 - 2.00 mm (0.057 - 0.078 in.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications > Page 2203 Valve Seat: Description and Operation "For information regarding this component please refer to Valve, Intake/Exhaust Description and Operation" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications > Page 2204 Valve Seat: Service and Repair "For information regarding this component please refer to Valve, Intake/Exhaust Service and Repair" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Valve Springs Free Length (Approximately) ........................................................................................................................................... 51.4 mm (2.02 in.) Wire Diameter ...................................................................................................................................... ............................... 3.95 - 4.77 mm (0.15 - 0.19 in.) Number of Coils ................................................................................................................................... ........................................................................... 7.52 Spring Tension (Valve Closed) ................................................................................................................................................. 376.4 424.4 N @ 41.9 mm .............................................................................................................................................................. ............... (84.6 - 95.6 lbs. @ 1.65 in.) Installed Height .................................................................................................................................... ............................... 41.1 - 42.7 mm (1.61 - 1.68 in.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2208 Valve Spring: Description and Operation VALVE SPRINGS DESCRIPTION There are two interchangeable, floating (spring rotates during operation), valve spring designs. Type A may be identified by the counterclockwise (spring spirals down and to the left) appearance, And Type B may be identified by the clockwise (spring spirals down and to the right) appearance. Both of the valve springs are a bee-hive shaped design but have different specifications (Fig. 18). The springs are seated on a steel washer on the cylinder head with retainers and locks retaining the springs (Fig. 19). The springs are installed with the smaller diameter against spring retainer (Fig. 18). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications > Page 2209 OPERATION The valve spring returns the valve against its seat for a positive seal of the combustion chamber. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > In Vehicle Service Valve Spring: Service and Repair In Vehicle Service REMOVAL - CYLINDER HEAD ON 1. Disconnect negative cable from battery. 2. Remove spark plug wires and all spark plugs. 3. Remove cylinder head cover(s). (Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL) 4. Remove rocker arms and shaft. (Refer to ENGINE/CYLINDER HEAD/ROCKER ARMS REMOVAL) 5. Rotate engine until the piston in the cylinder bore requiring spring removal is at TDC. 6. Install Special Tool 8453 to the cylinder head (Fig. 21). Tighten the attaching bolts to 23 Nm (200 inch lbs.). 7. Install a spark plug adapter in the spark plug hole. Connect air hose that can supply 620.5 - 689 kPa (90 - 100 psi) of air pressure to adapter. This is to hold valves in place while servicing components. 8. Locate the forcing screw and spring retainer adapter assembly over the spring requiring removal (Fig. 21). 9. Slowly turn the forcing screw clockwise (compressing the valve spring) until the valve keepers can be removed. 10. Turn forcing screw counterclockwise to relieve spring tension. Remove retainer and valve spring. 11. Repeat procedure for each cylinder requiring valve spring removal. INSPECTION NOTE: The are two different types of valve springs used that are interchangeable, but have different specifications(Refer to - ENGINE CYLINDER Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > In Vehicle Service > Page 2212 HEADVALVE SPRINGS - DESCRIPTION). Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested (Fig. 22). As an example; the compression length of a spring to be tested is 38.00 mm (1.496 inch). Turn the table of Tool C-647 until surface is in line with the 38.00 mm (1.496 inch) mark on the threaded stud and the zero mark on the front. Place spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to Engine Specifications to obtain specified height and allowable tensions (Refer to ENGINE SPECIFICATIONS). Replace any springs that do not meet specifications. INSTALLATION - CYLINDER HEAD ON 1. The intake valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem as guide. Do Not Force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks (Fig. 23). CAUTION: Do not pinch seal between retainer and top of valve guide. 2. Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-2-3-4-5-6. Make sure piston in cylinder is at TDC on the valve spring that is being covered. 3. Remove spark plug adapter tool. 4. Install rocker arms and shaft assembly (Refer to ENGINE/CYLINDER HEAD/ROCKER ARMS INSTALLATION) 5. Install cylinder head covers. (Refer to ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION) 6. Install spark plugs and connect wires. 7. Connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > In Vehicle Service > Page 2213 Valve Spring: Service and Repair Off Vehicle Service REMOVAL - CYLINDER HEAD OFF 1. With the cylinder head on a bench, position Special Tool C-3422-D with Adapter on the valve and spring retainer (Fig. 20). 2. Compress the spring only enough to remove the valve retainer locks. 3. Slowly release the spring tension and remove the valve spring and retainer. 4. For removal of the valve stem seal (Refer to ENGINE/CYLINDER HEADVALVE STEM SEALS REMOVAL). INSPECTION NOTE: The are two different types of valve springs used that are interchangeable, but have different specifications(Refer to - ENGINE CYLINDER HEADVALVE SPRINGS - DESCRIPTION). Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested (Fig. 22). As an example; the compression length of a spring to be tested is 38.00 mm (1.496 inch). Turn the table of Tool C-647 until surface is in line with the 38.00 mm (1.496 inch) mark on the threaded stud and the zero mark on the front. Place spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by two. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Refer to Engine Specifications to obtain specified height and allowable tensions (Refer to ENGINE SPECIFICATIONS). Replace any springs that do not meet specifications. INSTALLATION - CYLINDER HEAD OFF 1. If removed, install a new valve stem seal (Refer to - ENGINE/CYLINDER HEAD/VALVE STEM SEALS - INSTALLATION). 2. Position valve spring and retainer on spring seat. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > In Vehicle Service > Page 2214 3. Using Special Tool C-3422-D with Adapter (Fig. 20), compress the spring only enough to install the valve retainer locks. Install valve retainer locks. 4. Slowly release the spring tension. Ensure the retainer locks are seated properly (Fig. 23). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Valve Lift (Zero Lash) Intake ................................................................................................................................................... .............................................. 9.80 mm (0.385 in.) Exhaust ................................................................ .............................................................................................................................. 9.80 mm (0.385 in.) Face Angle Intake ................................................................................................................................................... .............................................................. 45 - 45.5 ° Exhaust ............................................................... ............................................................................................................................................... 45 45.5 ° Head Diameter Intake ................................................................................................................................................... ........................ 47.87 - 48.13 mm (1.88 - 1.89 in.) Exhaust ................................................................ ........................................................................................................ 35.37 - 35.63 mm (1.39 - 1.40 in.) Valve Margin Intake ................................................................................................................................................... .................... 0.825 - 0.973 mm (0.032 - 0.038 in.) Exhaust ................................................................ .................................................................................................... 1.565 - 1.713 mm (0.061 - 0.067 in.) Valve Length (Overall) Intake ................................................................................................................................................... ...................... 125.84 - 126.6 mm (4.95 - 4.98 in.) Exhaust ................................................................ ...................................................................................................... 127.2 - 127.96 mm (5.00 - 5.04 in.) Valve Stem Tip Height (valve tip to spring seat washer) Intake ................................................................................................................................................... ............................ 48.1 - 49.7 mm (1.89 - 1.95 in.) Exhaust ................................................................ ........................................................................................................ 48.53 - 50.09 mm (1.91 - 1.97 in.) Valve Stem Diameter Intake (Standard) ................................................................................................................................................. 6.935 6.953 mm (0.2730 - 0.2737 in.) Exhaust (Standard) .............................................................................................................................................. 6.906 6.924 mm (0.2718 - 0.2725 in.) Valve Stem to Guide Clearance Intake Standard .......................................................................................................................................................... 0.025 - 0.065 mm (0.001 - 0.0025 in.) Maximum Allowable (Rocking Method) ................................................................................................................................... 0.247 mm (0.010 in.) Exhaust Standard .......................................................................................................................................................... 0.059 - 0.094 mm (0.002 - 0.0037 in.) Maximum Allowable (Rocking Method) ................................................................................................................................... 0.414 mm (0.016 in.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications > Page 2218 Valve: Description and Operation INTAKE/EXHAUST VALVES & SEATS DESCRIPTION The valves have chrome plated valve stems with four-bead lock grooves. The valve stem seals are made of Viton rubber. OPERATION The two valves per cylinder are opened using hydraulic lifters, push rods, and rocker arms. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Valve: Initial Inspection and Diagnostic Overview VALVES 1. Clean and inspect valves thoroughly. Replace burned, warped and cracked valves. 2. Measure valve stems for wear (Fig. 16). For valve specifications, (Refer to - ENGINE SPECIFICATIONS). NOTE: Valve stems are chrome plated and should not be polished (Fig. 16). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2221 Valve: Component Tests and General Diagnostics VALVE GUIDES 1. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. 2. Measure valve stem-to-guide clearance as follows: 3. Install valve into cylinder head so it is 15 mm (0.590 inch) off the valve seat. A small piece of hose may be used to hold valve in place. 4. Attach dial indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being measured (Fig. 17). 5. Move valve to and from the indicator. For clearance specifications, (Refer to - ENGINE - SPECIFICATIONS). NOTE: Replace cylinder head if stern-to-guide clearance exceeds specifications, or if guide is loose in cylinder head. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation Valve: Service and Repair Removal and Installation REMOVAL 1. With cylinder head removed, compress valve springs using Valve Spring Compressor Tool C-3422-D with adapter 8464 (Refer to - ENGINE SPECIAL TOOLS). 2. Remove valve retaining locks. 3. Slowly release valve spring compressor. Remove valve spring retainer, valve spring, and valve stem seal. 4. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure installation in original location. INSTALLATION 1. Coat valve stems with clean engine oil and insert them in cylinder head. 2. Install valve spring seat on head (Fig. 19). 3. Install new seals on all valve stems and over valve guides (Fig. 19). Install valve springs and valve retainers (Fig. 19). 4. Install the valve springs. (Refer to ENGINE/CYLINDER HEADVALVE SPRINGS INSTALLATION) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 2224 Valve: Service and Repair Cleaning CLEANING 1. Clean all valves thoroughly and discard burned, warped and cracked valves. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 2225 Valve: Service and Repair Refacing Valves & Seats STANDARD PROCEDURE - REFACING VALVES AND VALVE SEATS The intake and exhaust valves and seats are machined to specific angles (Fig. 11). VALVES 1. Inspect the remaining margin after the valves are refaced (Fig. 12). (Refer to - ENGINE SPECIFICATIONS) VALVE SEATS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 2226 CAUTION: Remove metal from valve seat only. Do not remove material from cylinder head (Fig. 13). 1. When refacing valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained. 2. Measure the concentricity of valve seat using dial indicator (Fig. 14). Total runout should not exceed 0.051 mm (0.002 inch) total indicator reading. 3. Inspect the valve seat using Prussian blue to determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian blue then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center of valve face, contact is satisfactory. If the blue is transferred to top edge of valve face, lower valve seat with a 15 degree stone. If the blue is transferred to the bottom edge of valve face raise valve seat with a 65 degrees stone. NOTE: Valve seats which are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise cylinder head must be replaced. 4. When seat is properly positioned the width of intake and exhaust seats should be 1.50 - 2.00 mm (0.059 - 0.078 inch) (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Removal and Installation > Page 2227 5. After grinding the valve seats or faces, install the valve in cylinder head and check valve installed height by measuring from valve tip to spring seat (Fig. 15). Remove valve from cylinder head and grind valve tip until within specifications. Check valve tip for scoring. The tip chamfer should be reground (if necessary) to prevent seal damage when the valve is installed. 6. Check the valve spring installed height after refacing the valve and seat (Fig. 15). If valves and/or seats are reground, measure the installed height of springs (Fig. 15), make sure measurements are taken from top of spring seat to the bottom surface of spring retainer. If height is greater than specifications, install a 0.794 mm (0.0312 inch) spacer in head counterbore to bring spring height back within specifications. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 2232 Drive Belt: Description and Operation DRIVE BELTS DESCRIPTION The drive belts are a Poly-V type belt. Belt widths vary depending on the various engine and accessory packages. Satisfactory performance of these belts depends on belt condition and proper belt tension. OPERATION The accessory drive belts form the link between the engine crankshaft and the engine driven accessories. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 2233 Drive Belt: Testing and Inspection ACCESSORY DRIVE BELT Part 1 of 2 Part 2 of 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 2234 Drive Belt: Service and Repair DRIVE BELTS REMOVAL 1. Raise vehicle on hoist. Fig.8 2. Remove the drive belt shield (Fig. 8). WARNING: DO NOT ALLOW DRIVE BELT TENSIONER TO SNAP BACK, AS DAMAGE TO TENSIONER AND/OR PERSONAL INJURY COULD RESULT. Fig.9 3. Position a wrench on the belt tensioner lug (Fig. 9). 4. Release belt tension by rotating the tensioner counterclockwise (Fig. 9). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 2235 Fig.11 5. Remove the drive belt (Fig. 11). 6. Carefully return tensioner to its relaxed position. CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease, and coolants before installing the drive belt. INSPECTION Belt replacement under any or all of the following conditions is required: Excessive wear - Frayed cords - Severe glazing Fig.10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 2236 Poly-V Belt system may develop minor cracks across the ribbed side (due to reverse bending). These minor cracks are considered normal and acceptable. Parallel cracks are not (Fig. 10). NOTE: Do not use any type of belt dressing or restorer on Poly-V Belts. INSTALLATION 1. Route and position the drive belt onto all pulleys, except for the crankshaft (Fig. 11). 2. Rotate belt tensioner counterclockwise until belt can be installed onto the crankshaft pulley (Fig. 9). Slowly release belt tensioner. 3. Verify belt is properly routed and engaged on all pulleys. 4. Install drive belt shield (Fig. 8) and lower vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Accessory Drive Belt Tensioner Assembly ........................................................................................................................................... 28 Nm (250 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 2240 Drive Belt Tensioner: Service and Repair BELT TENSIONER REMOVAL 1. Raise vehicle on hoist. 2. Remove the drive belt shield. 3. Remove the drive belt. Fig.2 4. Remove the belt tensioner (Fig. 2). INSTALLATION 1. Install the belt tensioner and bolt (Fig. 2). Tighten bolt to 28 Nm (250 in. lbs.). 2. Install the drive belt. 3. Install the drive belt shield. 4. Lower the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Description and Operation Engine Mount: Description and Operation DESCRIPTION Fig.91 The engine mounting system consists of four mounts; right and a left side support the powertrain, and a front and a rear mount control powertrain torque. The right side mount is a hydro-type (Fig. 91), all others are of molded rubber material. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount Engine Mount: Service and Repair Front Mount FRONT MOUNT REMOVAL 1. Support the engine and transmission assembly with a floor jack so it will not rotate. Fig.92 2. Remove the front engine mount through bolt from the insulator and front crossmember mounting bracket (Fig. 92). 3. Remove six screws from air dam to allow access to the front mount screws. 4. Remove the front engine mount screws and remove the insulator assembly (Fig. 92). 5. Remove the front mounting bracket, if necessary (Fig. 92). INSTALLATION 1. Install the front mounting bracket, if removed (Fig. 92). 2. Install the front engine mount through bolt from the insulator and front crossmember mounting bracket (Fig. 92). 3. Install the insulator assembly and mounting screws (Fig. 92). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2246 Engine Mount: Service and Repair Left Mount LEFT MOUNT REMOVAL 1. Raise the vehicle on hoist. 2. Remove the left front wheel. 3. Remove the left mount through bolt access cover. 4. Support the transaxle with a suitable jack. 5. Remove the engine front mount through bolt to allow left mount removal clearance (Fig. 92). Fig.92 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2247 6. Remove the left mount through frame rail bolt (Fig. 93). 7. Lower transaxle for access to horizontal bolts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2248 8. Remove the horizontal bolts from the mount to the transaxle (Fig. 94) or (Fig. 95). NOTE: To remove mount, additional lowering of transaxle may be required. 9. Remove left mount. INSTALLATION 1. Install left mount on transaxle (Fig. 94) or (Fig. 95). 2. Raise transaxle with jack until left mount is in position. 3. Install left mount through bolt (Fig. 93). 4. Install left mount through bolt access cover. 5. Install front mount through bolt (Fig. 92). 6. Install left front wheel. 7. Lower vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2249 Engine Mount: Service and Repair Rear Mount REAR MOUNT REMOVAL 1. Raise vehicle on hoist. Fig.96 2. Remove the rear mount heat shield (Fig. 96). Fig.97 3. Remove the through bolt from the mount and rear mount bracket (Fig. 97). 4. Remove the mount bolts (Fig. 97). 5. Remove the rear mount (Fig. 97). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2250 Fig.98 6. For rear mount bracket removal, remove the bolts attaching bracket to transaxle (Fig. 98). 7. Remove rear mount bracket. INSTALLATION 1. Install rear mount bracket, if removed (Fig. 98). 2. Install the rear mount and bolts (Fig. 97). Tighten bolts to 54 Nm (40 ft. lbs.). 3. Install the mount through bolt to the mount and bracket (Fig. 97). Tighten through bolt to 54 Nm (40 ft. lbs.). 4. Install the rear mount heat shield (Fig. 96). 5. Lower vehicle on hoist. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Front Mount > Page 2251 Engine Mount: Service and Repair Right Mount RIGHT MOUNT REMOVAL 1. Remove air cleaner housing lid and clean air hose from throttle body. 2. Remove air cleaner element and housing. 3. Disconnect make-up air hose from cylinder head cover. 4. Remove the load on the right engine mount by carefully supporting the engine assembly with a floor jack. 5. Disconnect electrical harness support clips from engine mount bracket. Fig.99 6. Remove the bolts attaching the engine mount to the frame rail (Fig. 99). 7. Remove the three bolts attaching the engine mount to the engine bracket (Fig. 99). 8. Remove the right engine mount (Fig. 99). INSTALLATION 1. Install engine bracket (if removed). Tighten bolts to 33 Nm (24 ft. lbs.). 2. Position right engine mount and install frame rail to mount bolts (Fig. 99). Tighten bolts to 68 Nm (50 ft. lbs.). 3. Install the mount to engine bracket bolts and tighten to 54 Nm (40 ft. lbs.). (Fig. 99) 4. Connect electrical harness support clips to engine mount bracket. 5. Remove jack from under engine. 6. Connect make-up air hose to cylinder head cover. 7. Install air cleaner housing and element. 8. Install air cleaner housing lid and clean air tube to throttle body. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Lubrication At Curb Idle Speed* (Minimum with engine at operating temperature) ............................................................................................................................. 34.47 kPa (5 psi) At 3000 RPM ....................................................................................................................................... ................................... 205-551 kPa (30-80 psi) Oil Filter By-Pass Valve Setting ..................................................................................................................................................... 62-103 kPa (9-15 psi) Oil Pressure Switch Actuating Pressure .............................................................................................................................................. 14-28 Kpa (2-4 psi) caution: *If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 2256 Engine Oil Pressure: Testing and Inspection ENGINE OIL PRESSURE 1. Disconnect and remove oil pressure switch. 2. Install Special Tools C-3292 Gauge with 8406 Adaptor. 3. Start engine and record oil pressure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications Engine Oil Dip Stick - Dip Stick Tube: Specifications Oil Dipstick Housing Bolts ................................................................................................................... ...................................................... 48 Nm 35 ft. lbs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Oil Pan Drain Plug ............................................................................................................................... .................................................... 27 Nm (20 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2267 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2268 Engine Oil: Technical Service Bulletins Engine - Oil Quality/Viscosity Requirements NUMBER: 09-013-04 GROUP: Engine DATE: August 6, 2004 SUBJECT: Gasoline Engine Oil Quality And Viscosity Grades MODELS: 2005 (ND) Dakota 2005 (CS) Pacifica 2005 (DR) Ram Truck 2005 (HB) Durango 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2005 (KJ) Liberty 2005 (LX) 300/Magnum 2005 (PL) Neon 2005 (PT) PT Cruiser 2005 (RS) Town & Country/ Caravan/Voyager 2005 (TJ) Wrangler 2005 (WK) Grand Cherokee NOTE: This information applies to U.S. and Canada markets only. NOTE: For additional information and vehicles not covered by this Service Bulletin refer to the service information or the Owner Manual. DISCUSSION: This bulletin involves the engine oil to be used to service Chrysler Group gasoline engines. This symbol, found on the front of the container, means that the oil quality has been certified by the American Petroleum Institute (API) (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2269 Only use API Certified engine oils that meet the requirements of Chrysler's Material Standard MS-6395. MS-6395 contains requirements, not addressed by API Certification, that provide additional protection for Chrysler Group engines. All Chrysler Group gasoline engines, irrespective of model year, should be serviced with API Certified engine oils meeting MS-6395. Chrysler Group Engines are developed, certified and filled with engine oil of the designated viscosity grade, meeting MS-6395, and should be serviced with the correct viscosity grade engine oil. The following table contains the correct viscosity grades for the 2005 model year. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil and Filter ............................................................................................................................ ...................................................... 4.7Liters (5.0 Qt) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2272 Engine Oil: Fluid Type Specifications This Information has been updated by TSB 09-13-04. Engine Oil Type ................................................................................................................................... ....................................................................... 5W-20 Note: Only use API Certified engine oils that meet the requirements of Chrysler's Material Standard MS-6395. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check Engine Oil: Service and Repair Engine Oil Level Check ENGINE OIL LEVEL CHECK The best time to check engine oil level is after it has sat overnight, or if the engine has been running, allow the engine to be shut off for at least 5 minutes before checking oil level. Fig.102 Checking the oil while the vehicle is on level ground will improve the accuracy of the oil level reading (Fig. 102). Add only when the level is at or below the ADD mark. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Service and Repair > Engine Oil Level Check > Page 2275 Engine Oil: Service and Repair Engine Oil and Filter Change ENGINE OIL AND FILTER CHANGE Change engine oil at mileage and time intervals. WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Open hood, remove oil fill cap. 3. Hoist and support vehicle on safety stands. Fig.101 4. Place a suitable drain pan under crankcase drain (Fig. 101). 5. Remove drain plug from crankcase (Fig. 101) and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. 6. Remove oil filter. 7. Install and tighten drain plug in crankcase. 8. Install new oil filter. 9. Lower vehicle and fill crankcase with specified type and amount of engine oil. 10. Install oil fill cap. 11. Start engine and inspect for leaks. 12. Stop engine and inspect oil level. NOTE: Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications Oil Cooler: Specifications Oil Cooler Attachment Fitting ............................................................................................................... ................................................... 27 Nm (20 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications > Page 2279 Oil Cooler: Description and Operation OIL COOLER & LINES DESCRIPTION Fig.104 An engine oil cooler is used on 3.3/3.8L engines (Heavy Duty Cooling Only) (Fig. 104). The cooler is a coolant-to-oil type and mounted between the oil filter and engine block. OPERATION Engine oil travels from the oil filter and into the oil cooler. Engine oil then exits the cooler into the main gallery. Engine coolant flows into the cooler from the heater return tube and exits into the water pump inlet. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications > Page 2280 Oil Cooler: Service and Repair Oil Cooler & Lines REMOVAL 1. Drain cooling system. Fig.103 2. Disconnect oil cooler inlet and outlet hoses (Fig. 103). 3. Remove oil filter. Fig.104 4. Remove oil cooler attachment fitting (Fig. 104). 5. Remove oil cooler. INSTALLATION 1. Lubricate seal and position oil cooler to connector fitting on oil filter adapter (Fig. 104). NOTE: Position the flat side of oil cooler parallel to oil pan rail. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications > Page 2281 2. Install oil cooler attachment fitting and tighten to 27 Nm (20 ft. lbs.) (Fig. 104). 3. Install oil filter. 4. Connect oil cooler inlet and outlet hoses (Fig. 103). 5. Fill cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil Filter Attachment Fitting ................................................................................................................. ................................................... 54 Nm (40 ft. lbs.) Oil Filter ............................................................................................................................................... .................................................... 20 Nm (15 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications > Page 2285 Oil Filter: Service and Repair REMOVAL CAUTION: When servicing the oil filter avoid deforming the filter can by installing the remove/install tool band strap against the can-to-base lock seam. The lock seam joining the can to the base is reinforced by the base plate. Fig.105 1. Using suitable oil filter wrench, turn filter counterclockwise to remove from oil filter adapter (Fig. 105). Properly discard used oil filter. INSTALLATION 1. Wipe oil filter adapter base clean and inspect gasket contact surface. 2. Lubricate gasket of new filter with clean engine oil. 3. Install new filter until gasket contacts base (Fig. 105). Tighten filter 1 turn or 20 Nm (15 ft. lbs.). Use filter wrench if necessary. 4. Start engine and check for leaks. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications Oil Filter Adapter Bolts ......................................................................................................................... ................................................ 28 Nm (250 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications > Page 2289 Oil Filter Adapter: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Remove the oil filter. Fig.105 3. Disconnect oil pressure switch electrical connector. 4. Remove oil filter adapter attaching bolts (Fig. 105). 5. Remove oil filter adapter and seal (Fig. 105). INSTALLATION 1. Clean oil filter adapter and install new seal. 2. Position adapter on engine block and install bolts (Fig. 105). 3. Tighten adapter bolts to 28 Nm (250 in. lbs.). 4. Connect oil pressure switch electrical connector (Fig. 105). 5. Install the oil filter. 6. Lower vehicle on hoist. 7. Start engine and allow to run approximately 2 minutes. 8. Turn off engine and check oil level. Adjust oil level as necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Description and Operation Oil Line: Description and Operation "For information regarding this component please refer to oil cooler description and operation" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Description and Operation > Page 2293 Oil Line: Service and Repair "For information regarding this component please refer to oil cooler service and repair" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts ........................................................................................................................................ ................................................. 12 Nm (105 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2297 Oil Pan: Service and Repair REMOVAL 1. Disconnect negative cable from battery and remove engine oil dipstick. 2. Raise vehicle on hoist and drain engine oil. 3. Remove drive belt splash shield. Fig.106 4. Remove strut to transaxle attaching bolt (Fig. 106). Loosen strut to engine block attaching bolts. 5. Remove transaxle case cover (Fig. 106). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2298 Fig.107 6. Remove oil pan fasteners (Fig. 107). 7. Remove the oil pan and gasket (Fig. 107). CLEANING 1. Clean oil pan with solvent and wipe dry with a clean cloth. 2. Clean all gasket material from mounting surfaces of pan and block. 3. Clean oil screen and pick-up tube in clean solvent. INSPECTION 1. Inspect oil drain plug and plug hole for stripped or damaged threads and repair as necessary. Install a new drain plug gasket. Tighten to 27 Nm (20 ft. lbs.). 2. Inspect oil pan mounting flange for bends or distortion. Straighten flange if necessary. 3. Inspect condition of oil screen and pick-up tube. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2299 Fig.108 1. Clean sealing surfaces and apply a 1/8 inch bead of Mopar Engine RTV GEN II at the parting line of the chain case cover and the rear seal retainer (Fig. 108). 2. Position a new pan gasket on oil pan (Fig. 107). 3. Install oil pan and tighten fasteners to 12 Nm (105 in. lbs.) (Fig. 107). 4. Install cover to transaxle case (Fig. 106). 5. Install the strut bolt to transaxle housing (Fig. 106). Tighten all bending brace bolts. 6. Install the drive belt splash shield. 7. Lower vehicle and install oil dipstick. 8. Connect negative cable to battery. 9. Fill crankcase with oil to proper level. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil Pressure Switch ............................................................................................................................. .................................................. 23 Nm (200 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 2303 Oil Pressure Sender: Description and Operation DESCRIPTION The engine oil pressure switch is located on the lower left front side of the engine. It screws into the oil filter adapter. The normally closed switch provides an input through a single wire to the low pressure indicator light on the instrument cluster. OPERATION The oil pressure switch provides a ground for the instrument cluster low oil pressure indicator light. The switch receives oil pressure input from the engine main oil gallery. When engine oil pressure is greater than 27.5 Kpa (4 psi), the switch contacts open, providing a open circuit to the low pressure indicator light. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Specifications > Page 2304 Oil Pressure Sender: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Disconnect electrical connector from switch. 3. Remove oil pressure switch (Fig. 110). INSTALLATION 1. Install oil pressure switch. Torque oil pressure switch to 23 Nm (200 in. lbs.) (Fig. 110). 2. Connect electrical connector to switch. 3. Lower the vehicle. 4. Start engine and check for leaks. 5. Check engine oil level. Adjust as necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Oxygen Sensors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations > Page 2308 3.3-3.8 Liter Engine Front Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations > Page 2309 Engine Pressure Switch (GAS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID Oil Pressure Warning Lamp/Indicator: Application and ID BULB APPLICATION Oil Indicator (Base Cluster ................................................................................................................... ....................................................................... LED Oil Indicator ......................................................... ...................................................................................................................................................... PC74 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump Cover > Component Information > Specifications Oil Pump Cover: Specifications Oil Pump Cover Plate Bolts ................................................................................................................. ................................................. 12 Nm (105 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications Oil Pick Up/Strainer: Specifications Oil Pump Pick-up Tube Bolt ................................................................................................................ .................................................... 28 Nm (20 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Lubrication At Curb Idle Speed* (Minimum with engine at operating temperature) ............................................................................................................................. 34.47 kPa (5 psi) At 3000 RPM ....................................................................................................................................... ................................... 205-551 kPa (30-80 psi) Oil Filter By-Pass Valve Setting ..................................................................................................................................................... 62-103 kPa (9-15 psi) Oil Pressure Switch Actuating Pressure .............................................................................................................................................. 14-28 Kpa (2-4 psi) caution: *If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 2323 Engine Oil Pressure: Testing and Inspection ENGINE OIL PRESSURE 1. Disconnect and remove oil pressure switch. 2. Install Special Tools C-3292 Gauge with 8406 Adaptor. 3. Start engine and record oil pressure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Oil Pressure Regulator Valve > Component Information > Service and Repair Oil Pressure Regulator Valve: Service and Repair OIL PRESSURE RELIEF VALVE REMOVAL 1. Remove oil pan. Fig.109 2. Drill a 3.175 mm (1/8 in.) hole in the center of the retainer cap (Fig. 109). Insert a self-threading sheet metal screw into the cap. 3. Using suitable pliers, remove cap and discard. 4. Remove spring and relief valve (Fig. 109). INSTALLATION 1. Clean relief valve, spring and bore. NOTE: Lubricate relief valve with clean engine oil before installing. 2. Install relief valve and spring into housing. 3. Install new retainer cap until flush with sealing surface. 4. Install oil pan. 5. Fill crankcase with proper oil to correct level. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque Specifications Intake Manifold: Specifications Intake Manifold Torque Specifications LOWER INTAKE MANIFOLD 1. Tighten intake manifold end seal retainer screws to 12 Nm (105 in. lbs.). 2. Torque lower intake manifold bolts in 3 steps. Step 1: Tighten all bolts in sequence to 1 Nm (10 in. lbs.). Step 2: Tighten all bolts in sequence to 22 Nm (200 in. lbs.). Step 3: Tighten all bolts in sequence (again) to 22 Nm (200 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque Specifications > Page 2331 UPPER INTAKE MANIFOLD Tighten intake manifold bolts in sequence to 12 Nm (105 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Intake Manifold Torque Specifications > Page 2332 Intake Manifold: Specifications Throttle Body Bolt Torque Specifications Throttle Body Mounting Bolts .................................................................................................................................................... 11.8 Nm (105 ± 20 in. lbs) NOTE: The composite manifolds uses special Plastic screws. The factory installed Plastic screws can be removed and installed up to 5 times. Do not exceed the specified torque. These screws must be installed slowly (less than 600 rpms) to avoid melting the parent material. There are service repair screws available for repair. They require a higher torque than the original screws. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2333 Intake Manifold: Description and Operation DESCRIPTION Fig.123 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2334 Fig.127 The intake system is made up of an upper and lower intake manifold. The upper intake manifold is made of a composite for both the 3.3L engine and for the 3.8L engine (Fig. 123). The lower intake manifold is common between the two engines (Fig. 127). It also provides coolant crossover between cylinder heads and houses the coolant thermostat (Fig. 127). The intake manifold utilizes a compact design with very low restriction and outstanding flow balance. This design allows the engine to perform with a wide torque curve while increasing higher rpm horsepower. If, for some reason, the molded-in vacuum ports break, the composite manifold can be salvaged. The vacuum ports are designed to break at the shoulder, if overloaded. Additional material in the shoulder area provides sufficient stock to repair. Also, if the special screws that attach the MAP sensor, power steering reservoir, throttle cable bracket, and the EGR tube become stripped, an oversized screw is available to repair the stripped-out condition. OPERATION The intake manifold delivers air to the combustion chambers. This air allows the fuel delivered by the fuel injectors to ignite when the spark plugs fire. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2335 Intake Manifold: Testing and Inspection INTAKE MANIFOLD LEAKS An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning. WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE CLOTHING. 1. Start the engine. 2. Spray a small stream of water (Spray Bottle) at the suspected leak area. 3. If engine rpm's change, the area of the suspected leak has been found. 4. Repair as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Stripped Thread Repair Intake Manifold: Service and Repair Intake Manifold Stripped Thread Repair STRIPPED THREAD REPAIR The composite upper intake manifold thread bosses, if stripped out, can be repaired by utilizing a repair screw available through Mopar parts. Repair screws are available for the following manifold attached components: MAP sensor - Power steering reservoir - EGR tube - Throttle cable bracket The repair screws require a unique tightening torque specification from the original screw. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Stripped Thread Repair > Page 2338 Intake Manifold: Service and Repair Intake Manifold Vacuum Port Repair INTAKE MANIFOLD VACUUM PORT REPAIR The composite intake manifold vacuum ports, can be repaired. Although, if the manifold plenum chamber is damaged or cracked, the manifold must be replaced. To repair a broken or damaged vacuum nipple (port) on the composite intake manifold, perform the following procedure: NOTE: While performing this procedure, avoid getting the manifold material residue into the plenum chamber. 1. File or sand the remaining port back until a flat surface is obtained (plane normal to nipple (port) axis). Fig.119 2. Drill out the nipple (port) base using a 7/16" (brake booster port) or 11/32" (LDP/speed control port ) drill bit (Fig. 119). 3. Using a 1/4"-18 NPT (brake booster port) or 1/8"-18 NPT (LDP/speed control port) pipe tap, cut internal threads (Fig. 119). Use caution to start tap in a axis same as original nipple. 4. Apply Mopar Thread Sealant to threads of repair nipple(s). 5. Install repair nipple(s). Do not over torque repair nipple(s). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Stripped Thread Repair > Page 2339 Intake Manifold: Service and Repair Upper Intake Manifold REMOVAL- UPPER INTAKE MANIFOLD 1. Disconnect battery negative cable. 2. Disconnect Inlet Air Temperature (IAT) sensor electrical connector. 3. Remove air inlet resonator to throttle body hose assembly. 4. Disconnect throttle and speed control cables from throttle body. 5. Disconnect make-up air hose support clip from throttle cable bracket. 6. Disconnect the Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring connectors from throttle body. 7. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector. 8. Disconnect the vapor purge vacuum hose from throttle body. Fig.120 9. Disconnect the PCV hose (Fig. 120). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Stripped Thread Repair > Page 2340 Fig.121 10. Remove the power steering reservoir attaching bolts and only loosen the nut (Fig. 121). Lift reservoir up to disengage lower mount from stud. Set reservoir aside. Do not disconnect hose. Fig.122 11. Disconnect the brake booster and Leak Detection Pump (LDP) hoses from intake manifold (Fig. 122). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Stripped Thread Repair > Page 2341 Fig.123 12. Remove intake manifold bolts and remove the manifold (Fig. 123). 13. Cover the lower intake manifold with a suitable cover while the upper manifold is removed. 14. Clean and inspect the upper intake manifold. CLEANING 1. Discard gasket(s). 2. Clean all sealing surfaces. INSPECTION Check manifold for: Damage and cracks. - Mounting surface distortion by using a straightedge and thickness gauge. INSTALLATION - UPPER INTAKE MANIFOLD 1. If the following components were removed from manifold, install and tighten to specifications: CAUTION: The special screws used for the composite manifold attached components must be installed slowly using hand tools only. This requirement is to prevent the melting of material that causes stripped threads. If threads become stripped, an oversize repair screw is available. MAP sensor - 1.7 Nm (15 in. lbs.) - Throttle cable bracket - 5.6 Nm (50 in. lbs.) 2. Remove covering on lower intake manifold and clean surfaces. 3. Inspect manifold gasket condition. Gaskets can be re-used, if not damaged. To replace, remove gasket from upper manifold (Fig. 123). Position new gasket in seal channel and press lightly in-place. Repeat procedure for each gasket position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Stripped Thread Repair > Page 2342 Fig.124 4. Position upper manifold on lower manifold (Fig. 123). Install and tighten bolts to 12 Nm (105 in. lbs.) following torque sequence in (Fig. 124). 5. Connect the MAP sensor electrical connector. 6. Connect the brake booster and LDP vacuum hose to intake manifold (Fig. 122). CAUTION: The special screws used for attaching the EGR tube and power steering reservoir to the manifold must be installed slowly using hand tools only. This requirement is to prevent the melting of material that causes stripped threads. If threads become stripped, an oversize repair screw is available. 7. Install the power steering reservoir (Fig. 121). Tighten screws to manifold to 5.6 Nm (50 in. lbs.). 8. Connect throttle and speed control cables to throttle body. 9. Attach make up air hose clip into the hole in the throttle cable bracket. 10. Connect the wiring connectors to the Throttle Position Sensor (TPS) and Automatic Idle Speed (AIS) motor. 11. Install air cleaner and air inlet hose assembly. 12. Connect the Inlet Air Temperature (IAT) sensor electrical connector. 13. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Stripped Thread Repair > Page 2343 Intake Manifold: Service and Repair Lower Intake Manifold REMOVAL- LOWER INTAKE MANIFOLD 1. Perform fuel system pressure release procedure (before attempting any repairs). 2. Drain the cooling system. 3. Remove the upper intake manifold. 4. Remove the fuel line. Fig.125 5. Remove ignition coil and bracket (Fig. 125). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Stripped Thread Repair > Page 2344 Fig.126 6. Disconnect heater supply hose and engine coolant temperature sensor (Fig. 126). 7. Disconnect the fuel injector wire harness. 8. Remove the fuel injectors and rail assembly (Fig. 125). 9. Remove radiator upper hose. 10. Remove the intake manifold bolts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Stripped Thread Repair > Page 2345 Fig.127 11. Remove lower intake manifold (Fig. 127). WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE PERSONAL INJURY, HANDLE WITH CARE. 12. Remove intake manifold seal retainers screws (Fig. 127). Remove intake manifold gasket. 13. Inspect and clean manifold. CLEANING 1. Discard gasket(s). 2. Clean all sealing surfaces. INSPECTION Check for: Damage and cracks of each section. - Clogged water passages in end cross-overs (if equipped). - Check for cylinder head mounting surface distortion using a straightedge and thickness gauge. INSTALLATION - LOWER INTAKE MANIFOLD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Intake Manifold Stripped Thread Repair > Page 2346 Fig.128 1. Place a bead (approximately 1/4 inch diameter) of Mopar Engine RTV GEN II onto each of the four manifold to cylinder head gasket corners (Fig. 128). 2. Carefully install the new intake manifold gasket (Fig. 127). Tighten end seal retainer screws to 12 Nm (105 in. lbs.). Fig.129 3. Install lower intake manifold (Fig. 127). Install the bolts and torque to 1 Nm (10 in. lbs.). Then torque bolts to 22 Nm (200 in. lbs.) in sequence shown in (Fig. 129). Then torque again to 22 Nm (200 in. lbs.). After intake manifold is in place, inspect to make sure seals are in place. 4. Install the fuel injectors and rail assembly. 5. Connect fuel injector electrical harness. 6. Connect the engine coolant temperature sensor (Fig. 126). 7. Connect the heater supply (Fig. 126) and radiator upper hoses to manifold. 8. Connect the fuel line. 9. Install the upper intake manifold. 10. Connect negative battery cable. 11. Fill the cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID Oil Pressure Warning Lamp/Indicator: Application and ID BULB APPLICATION Oil Indicator (Base Cluster ................................................................................................................... ....................................................................... LED Oil Indicator ......................................................... ...................................................................................................................................................... PC74 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair REMOVAL 1. Remove the transaxle. 2. Remove the flex plate. Fig.67 3. Insert a 3/16 flat bladed pry tool between the dust lip and the metal case of the crankshaft seal. Angle the pry tool (Fig. 67) through the dust lip against metal case of the seal. Pry out seal. CAUTION: Do not permit the pry tool blade to contact crankshaft seal surface. Contact of the pry tool blade against crankshaft edge (chamfer) is permitted. INSTALLATION CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit sand paper to prevent seal damage during installation of new seal. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2355 Fig.68 1. Place Special Tool 6926-1 magnetic pilot tool on crankshaft (Fig. 68). 2. Place seal over Special Tool 6926-1 Pilot. Using Special Tool 6926-2 Installer with C-4171 Handle, drive seal into the retainer housing (Fig. 68). 3. Install the flex plate. 4. Install transaxle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Raise vehicle on hoist. Remove right wheel and inner splash shield. 3. Remove accessory drive belt. 4. Remove crankshaft damper. Fig.64 5. Position Special Tool 6341A on crankshaft nose. Carefully screw the tool into the seal until it engages firmly (Fig. 64). Be careful not to damage that crankshaft seal surface of cover Fig.65 6. Remove oil seal by turning the forcing screw until the seal disengages from the cover (Fig. 65). INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2359 Fig.66 1. Position Special Tool C-4992-2 Guide, on the crankshaft nose (Fig. 66). 2. Position new seal over the guide with the seal spring in the direction of the engine front cover (Fig. 66). 3. Install seal using Special Tool C-4992-1 until seal is flush with cover. (Fig. 66). 4. Install crankshaft damper. 5. Install accessory drive belt. 6. Install inner splash shield and right front wheel. 7. Lower vehicle and connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Description and Operation Valve Guide Seal: Description and Operation DESCRIPTION The valve stem seals are made of Viton rubber. The seals are positioned over the valve stem and seated on the valve guide (Fig. 28). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Description and Operation > Page 2363 Valve Guide Seal: Service and Repair VALVE STEM SEALS REMOVAL 1. Remove the valve springs. (Refer to ENGINE/CYLINDER HEAD/VALVE SPRINGS REMOVAL) 2. Remove the valve stem seal (Fig. 28). INSTALLATION 1. Install the valve stem seal squarely over the valve guide, using the valve stem as a guide (Fig. 28). Do not force the seal against top of the valve guide. 2. Install the valve spring. (Refer to - ENGINE/ CYLINDER HEADVALVE SPRINGS INSTALLATION). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil Pressure Switch ............................................................................................................................. .................................................. 23 Nm (200 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 2368 Oil Pressure Sender: Description and Operation DESCRIPTION The engine oil pressure switch is located on the lower left front side of the engine. It screws into the oil filter adapter. The normally closed switch provides an input through a single wire to the low pressure indicator light on the instrument cluster. OPERATION The oil pressure switch provides a ground for the instrument cluster low oil pressure indicator light. The switch receives oil pressure input from the engine main oil gallery. When engine oil pressure is greater than 27.5 Kpa (4 psi), the switch contacts open, providing a open circuit to the low pressure indicator light. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Specifications > Page 2369 Oil Pressure Sender: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Disconnect electrical connector from switch. 3. Remove oil pressure switch (Fig. 110). INSTALLATION 1. Install oil pressure switch. Torque oil pressure switch to 23 Nm (200 in. lbs.) (Fig. 110). 2. Connect electrical connector to switch. 3. Lower the vehicle. 4. Start engine and check for leaks. 5. Check engine oil level. Adjust as necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Oxygen Sensors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 2373 3.3-3.8 Liter Engine Front Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 2374 Engine Pressure Switch (GAS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Torque Torque Camshaft Sprocket Bolt 40 ft.lb Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications "Information not supplied by the manufacturer" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications > Page 2382 Crankshaft Gear/Sprocket: Service and Repair "For information regarding this component please refer to Timing chain service and repair" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications Timing Chain: Specifications Camshaft Sprocket Bolt 40 ft.lb Camshaft Thrust Plate Bolts 105 in.lb Crankshaft Damper Bolt 40 ft.lb Timing Chain Case Cover Bolts M8 Bolt 20 ft.lb M10 Bolt 40 ft.lb Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 2386 Timing Chain: Service Precautions Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 2387 Timing Chain: Service and Repair TIMING CHAIN AND SPROCKETS REMOVAL - TIMING CHAIN AND CAMSHAFT SPROCKET 1. Disconnect negative cable from battery. 2. Remove the timing chain cover. Fig.146 3. Rotate engine by turning crankshaft until the timing marks are aligned as shown in (Fig. 146). 4. Remove camshaft sprocket attaching bolt. 5. Remove the timing chain with camshaft sprocket. 6. Remove the crankshaft sprocket. REMOVAL - CRANKSHAFT SPROCKET 1. Remove the timing chain. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 2388 Fig.147 2. Using Special Tools 8539, 5048-6, and 5048-1, remove the crankshaft sprocket while holding the crankshaft from turning (Fig. 147). Be careful not to damage the crankshaft surfaces. INSTALLATION - CRANKSHAFT SPROCKET 1. Position the sprocket on the crankshaft (timing mark out) with the timing slot aligned with the timing pin. Fig.148 2. Install sprocket using Special Tool 8452 (Fig. 148). Install sprocket until it is fully seats on the crankshaft. 3. Install the timing chain and camshaft sprocket. INSTALLATION - TIMING CHAIN AND CAMSHAFT SPROCKET 1. Rotate crankshaft so the timing arrow is to the 12 o'clock position (Fig. 146). NOTE: Lubricate timing chain and sprockets with clean engine oil before installation. 2. While holding camshaft sprocket and chain in hand, place timing chain around the sprocket, aligning the plated link with the dot on the sprocket. Position the timing arrow to the 6 o'clock position (Fig. 146). 3. Place timing chain around crankshaft sprocket with the plated link lined up with the dot on the sprocket. Install camshaft sprocket into position. 4. Use a straight edge to check alignment of timing marks. 5. Install camshaft sprocket bolt and washer. Tighten bolt to 54 Nm (40 ft. lbs.). 6. Rotate crankshaft 2 revolutions and check timing mark alignment (Fig. 146). If timing marks do not line up, remove camshaft sprocket and realign. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Specifications > Page 2389 7. Install the timing chain cover. 8. Connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications "Information not supplied by the manufacturer" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Timing Chain Case Cover Bolts M8 Bolt 20 ft.lb M10 Bolt 40 ft.lb Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2396 Timing Cover: Service and Repair REMOVAL 1. Disconnect negative cable from battery. 2. Drain cooling system. 3. Raise vehicle on hoist. 4. Drain engine oil. 5. Remove right wheel and inner splash shield. 6. Remove oil pan. Fig.139 7. Remove oil pick-up tube (Fig. 139). 8. Remove accessory drive belt. 9. Remove A/C compressor and set aside. 10. Remove crankshaft vibration damper. 11. Remove radiator lower hose. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2397 Fig.140 Fig.141 12. Remove heater hose from timing chain cover housing (Fig. 140) or water pump inlet tube (if engine oil cooler equipped) (Fig. 141). 13. Remove the right side engine mount. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2398 Fig.142 14. Remove idler pulley from engine bracket (Fig. 142). 15. Remove the engine mount bracket (Fig. 142). 16. Remove camshaft position sensor from timing chain cover (Fig. 142). 17. Remove the water pump for cover removal clearance. Fig.143 18. Remove the bolt attaching the power steering pump support strut to the front cover (Fig. 143). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2399 Fig.144 19. Remove the timing chain cover fasteners. Remove timing chain cover (Fig. 144). INSTALLATION 1. Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs. Crankshaft oil seal must be removed to insure correct oil pump engagement. NOTE: DO NOT USE SEALER ON COVER GASKET 2. Position new gasket on timing cover (Fig. 144). Adhere new gasket to chain case cover, making sure that the lower edge of the gasket is flush to 0.5 mm (0.020 in.) passed the lower edge of the cover. 3. Rotate crankshaft so that the oil pump drive flats are in the vertical position. 4. Position oil pump inner rotor so the mating flats are in the same position as the crankshaft drive flats (Fig. 144). CAUTION: Make sure the oil pump is engaged on the crankshaft correctly or severe damage may result. 5. Install timing cover (Fig. 144). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2400 Fig.145 6. Install timing chain cover bolts. Tighten M8 bolts to 27 Nm (20 ft. lbs.) and M10 bolts to 54 Nm (40 ft. lbs.) (Fig. 145). 7. Install crankshaft front oil seal. 8. Install water pump and pulley. 9. Install crankshaft vibration damper. 10. Install engine mount bracket (Fig. 142) and tighten M10 to 54 Nm (40 ft. lbs.), M8 bolt to 28 Nm (21 ft. lbs. lbs.). 11. Install idler pulley on engine mount bracket (Fig. 142). 12. Install right side engine mount. 13. Install camshaft position sensor. 14. Connect the heater return hose at rear of timing chain cover (Fig. 140) or at water pump inlet tube (if engine oil cooler equipped) (Fig. 141). 15. Connect the radiator lower hose. 16. Install A/C compressor. 17. Install accessory drive belt. 18. Install oil pump pick-up tube with new O-ring. Tighten attaching bolt to 28 Nm (250 in. lbs.). 19. Install oil pan. 20. Install inner splash shield and right front wheel. 21. Fill crankcase with engine oil to proper level. 22. Fill cooling system. 23. Connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ............................... 400 kPa ± 34 kPa (58 psi ± 5 psi) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check Fuel Pressure: Testing and Inspection Fuel Delivery Check Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 2407 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 2408 Test 7 - 9 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specs - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump module - Fuel delivery system operation - Fuel pump relay fused B+ circuit - (A141) fuel pump relay output circuit open - (Z1) fuel pump ground circuit open/high resistance - Fuel pump module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 2409 Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test Test 1 - 2 SYMPTOM CHECKING FUEL PRESSURE LEAK DOWN POSSIBLE CAUSES - Checking fuel pressure - Fuel pump module - Checking fuel leak down Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications The cylinders are numbered from the front of the engine to the rear. The front cylinder bank is numbered 2, 4, 6. The rear cylinder bank is numbered 1, 3, 5. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 2414 Firing Order: Mechanical Specifications Firing Order 1-2-3-4-5-6 .............................................................................................................................................................. ......................................... Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations The cylinders are numbered from the front of the engine to the rear. The front cylinder bank is numbered 2, 4, 6. The rear cylinder bank is numbered 1, 3, 5. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set Ignition Cable: Customer Interest Engine Controls/Ignition - MIL ON/Misfire DTC's Set NUMBER: 18-018-04 GROUP: Vehicle Performance DATE: April 27, 2004 THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD JUNE, 2004. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303, P0304, P0305, P0306 OVERVIEW: This bulletin involves replacing the spark plugs, ignition wires and if necessary, reprogramming the Powertrain Control Module with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004 (MDH 0402XX). SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC's: ^ P0300-MULTIPLE CYLINDER MISFIRE ^ P0301-CYLINDER # 1 MISFIRE ^ P0302-CYLINDER # 2 MISFIRE ^ P0303-CYLINDER # 3 MISFIRE ^ P0304-CYLINDER # 4 MISFIRE ^ P0305-CYLINDER # 5 MISFIRE ^ P0306-CYLINDER # 6 MISFIRE DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform Repair Procedure 1 and if necessary, Repair Procedure 2. If an "Authorized Modification Label" is present and states that Service Bulletin 18-016-04 has been performed, it is not necessary to perform Repair Procedure 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 2427 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE 1: Replace spark plugs and ignition cables 1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service information available in TechCONNECT or the Town & Country and Caravan service manual (publication no. 81-370-04062CD), page 8I-10. 2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2. If Service Bulletin 18-016-04 has been performed, no further action is necessary. REPAIR PROCEDURE 2: Flash Reprogram PCM NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 2428 c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select 'Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 2429 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set Ignition Cable: All Technical Service Bulletins Engine Controls/Ignition - MIL ON/Misfire DTC's Set NUMBER: 18-018-04 GROUP: Vehicle Performance DATE: April 27, 2004 THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD JUNE, 2004. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303, P0304, P0305, P0306 OVERVIEW: This bulletin involves replacing the spark plugs, ignition wires and if necessary, reprogramming the Powertrain Control Module with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004 (MDH 0402XX). SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC's: ^ P0300-MULTIPLE CYLINDER MISFIRE ^ P0301-CYLINDER # 1 MISFIRE ^ P0302-CYLINDER # 2 MISFIRE ^ P0303-CYLINDER # 3 MISFIRE ^ P0304-CYLINDER # 4 MISFIRE ^ P0305-CYLINDER # 5 MISFIRE ^ P0306-CYLINDER # 6 MISFIRE DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform Repair Procedure 1 and if necessary, Repair Procedure 2. If an "Authorized Modification Label" is present and states that Service Bulletin 18-016-04 has been performed, it is not necessary to perform Repair Procedure 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 2435 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE 1: Replace spark plugs and ignition cables 1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service information available in TechCONNECT or the Town & Country and Caravan service manual (publication no. 81-370-04062CD), page 8I-10. 2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2. If Service Bulletin 18-016-04 has been performed, no further action is necessary. REPAIR PROCEDURE 2: Flash Reprogram PCM NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 2436 c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select 'Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 2437 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 2438 Ignition Cable: Description and Operation SPARK PLUG CABLE Spark Plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the ignition coil pack to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Check the spark plug cable connections for good contact at the coil, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean Spark Plug cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. The spark plug cables and spark plug boots are made from high temperature materials. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set Spark Plug: Customer Interest Engine Controls/Ignition - MIL ON/Misfire DTC's Set NUMBER: 18-018-04 GROUP: Vehicle Performance DATE: April 27, 2004 THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD JUNE, 2004. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303, P0304, P0305, P0306 OVERVIEW: This bulletin involves replacing the spark plugs, ignition wires and if necessary, reprogramming the Powertrain Control Module with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004 (MDH 0402XX). SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC's: ^ P0300-MULTIPLE CYLINDER MISFIRE ^ P0301-CYLINDER # 1 MISFIRE ^ P0302-CYLINDER # 2 MISFIRE ^ P0303-CYLINDER # 3 MISFIRE ^ P0304-CYLINDER # 4 MISFIRE ^ P0305-CYLINDER # 5 MISFIRE ^ P0306-CYLINDER # 6 MISFIRE DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform Repair Procedure 1 and if necessary, Repair Procedure 2. If an "Authorized Modification Label" is present and states that Service Bulletin 18-016-04 has been performed, it is not necessary to perform Repair Procedure 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 2447 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE 1: Replace spark plugs and ignition cables 1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service information available in TechCONNECT or the Town & Country and Caravan service manual (publication no. 81-370-04062CD), page 8I-10. 2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2. If Service Bulletin 18-016-04 has been performed, no further action is necessary. REPAIR PROCEDURE 2: Flash Reprogram PCM NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 2448 c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select 'Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 2449 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set Spark Plug: All Technical Service Bulletins Engine Controls/Ignition - MIL ON/Misfire DTC's Set NUMBER: 18-018-04 GROUP: Vehicle Performance DATE: April 27, 2004 THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD JUNE, 2004. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303, P0304, P0305, P0306 OVERVIEW: This bulletin involves replacing the spark plugs, ignition wires and if necessary, reprogramming the Powertrain Control Module with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004 (MDH 0402XX). SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC's: ^ P0300-MULTIPLE CYLINDER MISFIRE ^ P0301-CYLINDER # 1 MISFIRE ^ P0302-CYLINDER # 2 MISFIRE ^ P0303-CYLINDER # 3 MISFIRE ^ P0304-CYLINDER # 4 MISFIRE ^ P0305-CYLINDER # 5 MISFIRE ^ P0306-CYLINDER # 6 MISFIRE DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform Repair Procedure 1 and if necessary, Repair Procedure 2. If an "Authorized Modification Label" is present and states that Service Bulletin 18-016-04 has been performed, it is not necessary to perform Repair Procedure 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 2455 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE 1: Replace spark plugs and ignition cables 1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service information available in TechCONNECT or the Town & Country and Caravan service manual (publication no. 81-370-04062CD), page 8I-10. 2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2. If Service Bulletin 18-016-04 has been performed, no further action is necessary. REPAIR PROCEDURE 2: Flash Reprogram PCM NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 2456 c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select 'Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 2457 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications Spark Plug Resistance - 3.3/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 2460 Spark Plug: Mechanical Specifications Spark Plug - 3.3L/3.8L Torque Spark Plug Torque ............................................................................................................................... ................................................ 13 ft. lbs. (17.5 N.m) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2461 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. .................................................................RE14PLP5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2462 Spark Plug: Description and Operation STANDARD 4 CYLINDER All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Refer to Specifications for gap and type of spark plug. PLATINUM PLUGS The V6 engines use platinum resistor spark plugs. They have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. For spark plug identification and specifications, refer to Specifications. Do not use man ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Platinum Pads Setting Spark Electrode Gap When the spark plugs use a single or double platinum tips and they have a recommended service life of 100,000 miles for normal driving conditions per Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2463 schedule A. The spark plugs have a recommended service life of 75,000 miles for severe driving conditions per schedule B. A thin platinum pad is welded to both or just the center electrode end(s) as shown. Extreme care must be used to prevent spark plug cross threading, mis-gapping and ceramic insulator damage during plug removal and installation. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2464 Spark Plug: Service and Repair REMOVAL When replacing the spark plugs and spark plug cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. Always remove cables by grasping at the boot, rotating the boot 1/2 turn, and pulling straight back in a steady motion. 1. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. 2. Remove the spark plug using a quality socket with a foam insert. 3. Inspect the spark plug condition. INSTALLATION When replacing the spark plugs and spark plug cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. 1. Coat threads of spark plug with anti-seize. Be sure not to get anti-seize ANYWHERE BUT ON THE THREADS OF THE SPARK PLUG as shown. 2. To avoid cross threading, start the spark plug into the cylinder head by hand. 3. Tighten spark plugs to 17.5 N.m (13 ft. lbs.) torque. 4. Install spark plug cables over spark plugs. A click will be heard and felt when the cable properly attaches to the spark plug. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Cylinder Compression Pressure Cylinder Compression Pressure Minimum Compression Pressure 100 psi Maximum Variation Between Cylinders 25 % Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2468 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Remove the Auto Shutdown (ASD) relay from the PDC. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gauge adaptor Special Tool 8116 or the equivalent, into the # 1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer (Special Tool CH7059) with cable adaptors to the DRBIII. 7. Crank engine until maximum pressure is reached on gauge. Record this pressure as # 1 cylinder pressure. 8. Repeat the previous step for all remaining cylinders. 9. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 10. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 11. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Drive Pulley, Water Pump > Component Information > Specifications Drive Pulley: Specifications Water Pump Pulley Bolts ..................................................................................................................... ................................................. 28 Nm (250 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Bypass Hose > Component Information > Specifications Thermostat Bypass Hose: Specifications Pipe Bolts Intake Manifold ................................................................................................................... ................................................. 23 Nm (200 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2484 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System Capacity .................................................................................................................... ...................................................... 13.4 qts. (12.6L)* * Includes heater and coolant recovery bottle filled to MAX level - Add 2.9 qts. (2.8L) if equipped with a rear heater. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2487 Coolant: Fluid Type Specifications The use of aluminum cylinder blocks, cylinder heads, and water pumps requires special corrosion protection. Mopar Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene glycol base coolant with hybrid organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% Ethylene Glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. IMPORTANT: The green coolant MUST NOT BE MIXED with the orange or magenta coolants. When replacing coolant the complete system flush must be performed before using the replacement coolant. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 2488 Coolant: Service Precautions CAUTION: Mixing of coolants other than specified (non-HOAT), may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. If a non-HOAT coolant is introduced into the cooling system in an emergency, it should be replaced with the specified coolant as soon as possible. Do not use plain water alone or alcohol base antifreeze products. Do not use additional rust inhibitors or antirust products, as they may not be compatible with the radiator coolant and may plug the radiator. This vehicle has not been designed for use with Propylene Glycol based coolants. Use of Propylene Glycol based coolants is not recommended. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 2489 Coolant: Testing and Inspection COOLANT CONCENTRATION TESTING Coolant concentration should be checked when any additional coolant was added to system or after a coolant drain, flush and refill. The coolant mixture offers optimum engine cooling and protection against corrosion when mixed to a freeze point of -37 °C (-34 °F) to -46 °C (-50 °F). The use of a hydrometer or a refractometer can be used to test coolant concentration. A hydrometer will test the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and higher the freeze protection (up to a maximum of 60% by volume glycol). A refractometer (Special Tool 8286) will test the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufactures use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and is not recommended. CAUTION: Do not mix types of coolant-corrosion protection will be severely reduced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Drain Plug, Cylinder Block > Component Information > Specifications Coolant Drain Plug: Specifications Cylinder Block Drain Plugs .................................................................................................................. .................................................. 20 Nm (15 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > Recalls for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion Technical Service Bulletin # F01 Date: 060201 Campaign - Rear A/C/Heater Tube Corrosion February 2006 Dealer Service Instructions for: Customer Satisfaction Notification F01 Rear A/C and Heater Tube Corrosion Effective immediately all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 05-028 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2005 (RS) Dodge Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles equipped with rear Heater/Air Conditioning (sales code HBB) and Stow-n-Go seats (sales code CYC) or Stow-N-Go floor pan (sales code CYY or CYV). IMPORTANT: Only the above vehicles sold or currently registered in "salt belt" states (where large amounts of road salt are used for snow and ice removal) are involved. See "Owner Notification and Service Scheduling" section for a list of salt belt states. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The underbody rear A/C and heater tube mounting brackets on about 239,800 of the above vehicles may have insufficient corrosion protection. Excessive corrosion can cause the rear A/C or heater tubes to leak. This may result in either an inoperative A/C system or engine overheating. Engine damage can occur if an overheated engine continues to be driven. Repair The underbody rear A/C and heater tube assembly must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > Recalls for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 2501 Parts Information Completion Reporting and Reimbursement DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Only vehicles sold or currently registered in "Salt Belt" states (where large amounts of road salt are used for snow and ice removal) are involved. The Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > Recalls for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 2502 following states are "Salt Belt" states: Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the hood. 2. Using an approved refrigerant recovery machine, recover the refrigerant from the air conditioning system. Follow the manufacturers instructions provided with the machine being used. 3. Using a suitable clean container, drain the coolant from the engine cooling system. Save the coolant for reuse. 4. Raise the vehicle on an appropriate hoist. 5. Disconnect the exhaust system from the exhaust hanger rubber isolators and position the exhaust system out of the way. 6. Disconnect the underbody A/C lines from the front liquid and suction line extension tubes (Figure 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > Recalls for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 2503 7. Remove the nut that secures the underbody A/C lines to the rear evaporator tapping plate (Figure 2). 8. Disconnect the underbody A/C lines from the evaporator tapping plate. NOTE: The A/C line mounting block may not come loose after removing the retaining nut due to corrosion between the mounting block and the retaining stud. Do not use excessive force to attempt to remove the mounting block from the evaporator. Evaporator damage may occur. Using an air chisel with a flat nose bit, gently pull down on the A/C lines and then lightly rap on the end of the stud with the bit of the air chisel (Figure 3). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > Recalls for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 2504 9. Remove the fasteners that secure the four underbody line retaining straps to the vehicles underbody (Figure 4). 10. Remove the fastener that secures the right rear brake line bracket to the underbody (Figure 5). 11. Disconnect the underbody heater tubes at the rear of the vehicle by releasing the insert in the underbody heater tube quick connect fittings and Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > Recalls for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 2505 carefully pull downward on the heater tube fitting. CAUTION: Residual coolant will come out of the heater hoses when they are removed. Be prepared to catch the residual coolant in a suitable container. 12. Lower the underbody heater tubes to drain any residual coolant from the tubes. 13. Using spring tension clamp pliers (Blue Point(R) YA9562 or equivalent), compress and slide the clamps off the rubber hoses at the front of the underbody coolant tubes. 14. Disconnect the heater hoses by carefully twisting the hoses back and forth while gently pulling them away from the end of the coolant tubes. 15. Remove and discard the underbody rear A/C and heater tubes. 16. Using locking pliers, remove and discard the stud from the evaporator tapping plate. CAUTION: Failure to replace the stud will cause future A/C tube failure. The new stud has an additional coating to prevent corrosion. 17. Using an E7 Torx(R) socket (Snap-on(R) TLE70A or equivalent), install the new stud provided in the kit into the evaporator tapping plate (Figure 6). Tighten the stud to 80 in. lbs. (9 N.m). 18. Remove the plastic shipping cap on the A/C mounting block and pour 1 oz. of PAG oil (P/N 82300102) into the A/C suction line. Then temporarily reinstall the shipping cap. 19. Position the new line kit under the vehicle and install the fasteners that secure the four retaining straps to the vehicle. Tighten the fasteners to 65 in. lbs. (7 N.m). 20. Position the rear brake line bracket and install the fastener. Tighten the fastener to 250 in. lbs. (28 N.m). 21. Remove and discard the plastic shipping cap from the A/C mounting block and lubricate the new o-ring seals with clean refrigerant oil. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > Recalls for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 2506 22 Connect the underbody A/C lines to the rear evaporator tapping plate (Figure 7). 23. Install the new nut/washer, provided in the kit, to secure the underbody A/C line mounting block to the rear evaporator tapping plate (Figure 7). Tighten the nut to 17 ft. lbs. (23 N.m). 24. Remove the plastic shipping caps and lubricate the new o-ring seals for front extension tubes with clean refrigerant oil. 25. Connect the underbody A/C line fittings to the front liquid and suction line extension tubes. Tighten the A/C line brass nuts to 17 ft. lbs. (23 N.m). 26. Connect the rubber hoses at the front of the underbody heater tube hoses to the rear heater extension tubes. 27. Using spring tension clamp pliers (Blue Point® YA9562 or equivalent), compress and slide the clamps that secure the heater hoses over the extension tubes. Release the clamp when it is correctly positioned over the tube. 28. Connect the rear underbody heater quick connect fittings to the rear heater core extension tubes. 29. Place the exhaust system into position and attach the exhaust hanger rubber isolators. 30. Lower the vehicle from the hoist. 31. Using an approved refrigerant evacuation machine, evacuate the A/C system. Follow the manufacturers instructions provided with the machine being used. 32. Refill the engine cooling system using the original coolant removed from the vehicle. 33. Using an approved refrigerant charging machine, charge the A/C system. Follow the manufacturers instructions provided with the machine being used. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > Recalls for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 2507 NOTE: Refer to the underhood A/C charge label for the correct amount of refrigerant to install into the A/C system (Figure 8). 34. Remove the A/C charging machine, close the hood and return the vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > Recalls for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 2508 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion Technical Service Bulletin # F01 Date: 060201 Campaign - Rear A/C/Heater Tube Corrosion February 2006 Dealer Service Instructions for: Customer Satisfaction Notification F01 Rear A/C and Heater Tube Corrosion Effective immediately all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 05-028 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2005 (RS) Dodge Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles equipped with rear Heater/Air Conditioning (sales code HBB) and Stow-n-Go seats (sales code CYC) or Stow-N-Go floor pan (sales code CYY or CYV). IMPORTANT: Only the above vehicles sold or currently registered in "salt belt" states (where large amounts of road salt are used for snow and ice removal) are involved. See "Owner Notification and Service Scheduling" section for a list of salt belt states. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The underbody rear A/C and heater tube mounting brackets on about 239,800 of the above vehicles may have insufficient corrosion protection. Excessive corrosion can cause the rear A/C or heater tubes to leak. This may result in either an inoperative A/C system or engine overheating. Engine damage can occur if an overheated engine continues to be driven. Repair The underbody rear A/C and heater tube assembly must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 2514 Parts Information Completion Reporting and Reimbursement DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Only vehicles sold or currently registered in "Salt Belt" states (where large amounts of road salt are used for snow and ice removal) are involved. The Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 2515 following states are "Salt Belt" states: Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the hood. 2. Using an approved refrigerant recovery machine, recover the refrigerant from the air conditioning system. Follow the manufacturers instructions provided with the machine being used. 3. Using a suitable clean container, drain the coolant from the engine cooling system. Save the coolant for reuse. 4. Raise the vehicle on an appropriate hoist. 5. Disconnect the exhaust system from the exhaust hanger rubber isolators and position the exhaust system out of the way. 6. Disconnect the underbody A/C lines from the front liquid and suction line extension tubes (Figure 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 2516 7. Remove the nut that secures the underbody A/C lines to the rear evaporator tapping plate (Figure 2). 8. Disconnect the underbody A/C lines from the evaporator tapping plate. NOTE: The A/C line mounting block may not come loose after removing the retaining nut due to corrosion between the mounting block and the retaining stud. Do not use excessive force to attempt to remove the mounting block from the evaporator. Evaporator damage may occur. Using an air chisel with a flat nose bit, gently pull down on the A/C lines and then lightly rap on the end of the stud with the bit of the air chisel (Figure 3). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 2517 9. Remove the fasteners that secure the four underbody line retaining straps to the vehicles underbody (Figure 4). 10. Remove the fastener that secures the right rear brake line bracket to the underbody (Figure 5). 11. Disconnect the underbody heater tubes at the rear of the vehicle by releasing the insert in the underbody heater tube quick connect fittings and Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 2518 carefully pull downward on the heater tube fitting. CAUTION: Residual coolant will come out of the heater hoses when they are removed. Be prepared to catch the residual coolant in a suitable container. 12. Lower the underbody heater tubes to drain any residual coolant from the tubes. 13. Using spring tension clamp pliers (Blue Point(R) YA9562 or equivalent), compress and slide the clamps off the rubber hoses at the front of the underbody coolant tubes. 14. Disconnect the heater hoses by carefully twisting the hoses back and forth while gently pulling them away from the end of the coolant tubes. 15. Remove and discard the underbody rear A/C and heater tubes. 16. Using locking pliers, remove and discard the stud from the evaporator tapping plate. CAUTION: Failure to replace the stud will cause future A/C tube failure. The new stud has an additional coating to prevent corrosion. 17. Using an E7 Torx(R) socket (Snap-on(R) TLE70A or equivalent), install the new stud provided in the kit into the evaporator tapping plate (Figure 6). Tighten the stud to 80 in. lbs. (9 N.m). 18. Remove the plastic shipping cap on the A/C mounting block and pour 1 oz. of PAG oil (P/N 82300102) into the A/C suction line. Then temporarily reinstall the shipping cap. 19. Position the new line kit under the vehicle and install the fasteners that secure the four retaining straps to the vehicle. Tighten the fasteners to 65 in. lbs. (7 N.m). 20. Position the rear brake line bracket and install the fastener. Tighten the fastener to 250 in. lbs. (28 N.m). 21. Remove and discard the plastic shipping cap from the A/C mounting block and lubricate the new o-ring seals with clean refrigerant oil. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 2519 22 Connect the underbody A/C lines to the rear evaporator tapping plate (Figure 7). 23. Install the new nut/washer, provided in the kit, to secure the underbody A/C line mounting block to the rear evaporator tapping plate (Figure 7). Tighten the nut to 17 ft. lbs. (23 N.m). 24. Remove the plastic shipping caps and lubricate the new o-ring seals for front extension tubes with clean refrigerant oil. 25. Connect the underbody A/C line fittings to the front liquid and suction line extension tubes. Tighten the A/C line brass nuts to 17 ft. lbs. (23 N.m). 26. Connect the rubber hoses at the front of the underbody heater tube hoses to the rear heater extension tubes. 27. Using spring tension clamp pliers (Blue Point® YA9562 or equivalent), compress and slide the clamps that secure the heater hoses over the extension tubes. Release the clamp when it is correctly positioned over the tube. 28. Connect the rear underbody heater quick connect fittings to the rear heater core extension tubes. 29. Place the exhaust system into position and attach the exhaust hanger rubber isolators. 30. Lower the vehicle from the hoist. 31. Using an approved refrigerant evacuation machine, evacuate the A/C system. Follow the manufacturers instructions provided with the machine being used. 32. Refill the engine cooling system using the original coolant removed from the vehicle. 33. Using an approved refrigerant charging machine, charge the A/C system. Follow the manufacturers instructions provided with the machine being used. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 2520 NOTE: Refer to the underhood A/C charge label for the correct amount of refrigerant to install into the A/C system (Figure 8). 34. Remove the A/C charging machine, close the hood and return the vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Coolant Line/Hose: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 2521 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > Page 2522 Coolant Line/Hose: Specifications Water Pump Inlet Tube Bolts ............................................................................................................... ................................................. 28 Nm (250 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > Page 2523 Coolant Line/Hose: Service and Repair WATER PUMP INLET TUBE REMOVAL 1. Drain the cooling system. 2. Raise vehicle on hoist and remove the belt splash shield. Fig.34 3. Remove the radiator lower hose from inlet tube. Fig.35 4. Remove the oil cooler outlet/heater return hose from inlet tube (only if equipped with engine oil cooler). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Technical Service Bulletins > Page 2524 Fig.36 5. Remove the inlet tube bolts. 6. Remove the inlet tube. Discard the O-ring seal. INSTALLATION 1. Clean the inlet tube O-ring sealing surfaces on the timing cover housing and tube. 2. Apply Mopar Dielectric Grease or equivalent to the O-ring before installation. 3. Position new O-ring seal on inlet tube. 4. Install the inlet tube. Tighten bolts to 28 Nm (250 in. lbs.). 5. Connect radiator lower hose and heater return hose (if equipped with engine oil cooler) to the inlet tube. 6. Install the drive belt splash shield and lower vehicle. 7. Fill the cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Outlet > Component Information > Specifications Coolant Outlet: Specifications Coolant Outlet Connector/ Thermostat Housing Bolts .......................................................................................................................... 28 Nm (250 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation Coolant Reservoir: Description and Operation DESCRIPTION Fig.2 The coolant recovery/reserve system container is mounted in the engine compartment. The container is made of plastic. OPERATION The coolant recovery system works with the radiator pressure cap to use thermal expansion and contraction of the coolant to keep the coolant free of trapped air. Provides a convenient and safe method for checking coolant level and adjusting level at atmospheric pressure without removing the radiator pressure cap. It also provides some reserve coolant to cover deaeration, evaporation, or boiling losses. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Page 2531 Coolant Reservoir: Testing and Inspection COOLANT RECOVERY SYSTEM The cooling system is closed and designed to maintain coolant level to the top of the radiator. 1. With the engine off and cooling system not under pressure, drain several ounces of coolant from the radiator draincock while observing the coolant recovery container. Coolant level in the container should drop. 2. Remove the radiator pressure cap. The coolant level should be full to the top radiator neck. If not, and the coolant level in the container is at or above the MIN mark, there is an air leak in the coolant recovery system. 3. Check hose and hose connections to the container, radiator filler neck or the pressure cap seal to the radiator filler neck for leaks. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Page 2532 Coolant Reservoir: Service and Repair REMOVAL 1. Raise the vehicle on hoist. Fig.2 2. Remove the lower attaching screws. 3. Lower the vehicle. 4. Remove the upper attaching screw . 5. Disconnect recovery hose from container. 6. Remove the recovery container. INSTALLATION 1. Connect the recovery hose to container. 2. Position the recovery container on the frame rail. 3. Install the upper attaching screw and tighten to 7 Nm (60 in. lbs.). 4. Raise the vehicle on hoist. 5. Install the lower attaching screws and tighten to 8.5 Nm (75 in. lbs.). 6. Lower the vehicle. 7. Add coolant to container as necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Diagrams A/C Pressure Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids Radiator Cooling Fan Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and an Electrostatic Discharge Symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 2541 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 2542 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 2543 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagnostic Aids > Page 2544 Radiator Cooling Fan Motor: Connector Views Radiator Fan No.1 Radiator Fan No.2 Radiator Fan No.1 (Gas) Radiator Fan No.2 (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2545 Radiator Cooling Fan Motor: Description and Operation DESCRIPTION Fig.21 The dual radiator fans are mounted to the back side of the radiator. The radiator fan consist of the fan blade, electric motor and a support shroud which are all serviced as an assembly. Radiator Fan Operation Chart OPERATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2546 Radiator Fan Diagnosis Chart Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2547 Radiator Cooling Fan Motor: Service and Repair REMOVAL Fig.21 There are no repairs to be made to the fan or shroud assembly. If the fan is warped, cracked, or otherwise damaged, it must be replaced as an assembly. 1. Remove the radiator upper crossmember. 2. Disconnect the radiator fan electrical connectors. 3. Remove radiator fan(s) retaining screw . 4. Remove the radiator fan(s) by lifting upward to release from mounts. INSTALLATION 1. Install the radiator fan(s) into mounts and attaching clips on the radiator. 2. Install radiator fan(s) attaching screws. Tighten to 5 Nm (45 in. lbs.). 3. Connect the radiator fan(s) electrical connectors. 4. Install the radiator upper support crossmember. 5. Install the upper radiator mounts to the crossmember bolts, if removed. Tighten to 8 Nm (70 in. lbs.). 6. Install the radiator upper hose to the support clip (2.4L engine). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2553 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2554 Figure 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2555 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2556 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2557 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2558 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2559 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2560 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2561 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2562 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2563 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2564 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2565 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2566 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2567 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2568 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2569 Radiator Cooling Fan Motor Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and an Electrostatic Discharge Symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2570 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2571 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2572 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2573 Radiator Fan Realy (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2574 8w-42-20 (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 2575 Radiator Cooling Fan Motor Relay: Description and Operation DESCRIPTION Fig.22 The radiator fan relay is a solid state type and is located on the front bumper reinforcement. OPERATION The solid state radiator fan relay is controlled by the Powertrain Control Module (PCM) by way of a Pulse Width Modulated (PWM) signal. The relay control circuit supplies a 12 volt signal to the PCM. The PCM then pulses the ground circuit to achieve fan on time. The relay provides a voltage to the fan motors which is proportional to the pulse width it receives from the PCM. The duty cycle ranges from 30% for low speed operation, then ramps-up to 100% for high speed operation. This fan control system provides infinitely variable fan speeds, allowing for improved fan noise, A/C performance, better engine cooling, and additional vehicle power. To control operation of the relay, the PCM looks at inputs from: ^ Engine coolant temperature ^ A/C pressure transducer ^ Ambient temperature from the body controller ^ Vehicle speed ^ Transmission oil temperature The PCM uses these inputs to determine when the fan should operate and at what speed. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 2576 Radiator Cooling Fan Motor Relay: Testing and Inspection Test 1 - 3 SYMPTOM CHECKING RADIATOR FAN RELAY OUTPUT POSSIBLE CAUSES - Radiator Fan Relay Operation - Ground Circuit Open - Radiator Fan Relay Output Circuit - Radiator Fan Assembly Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 2577 Radiator Cooling Fan Motor Relay: Service and Repair REMOVAL Fig.22 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Remove the radiator crossmember to front fascia closure panel. 4. Disconnect the relay electrical connector. 5. Remove the rivet attaching the relay to the front bumper beam. 6. Remove the relay. INSTALLATION CAUTION: The relay mounting location is designed to dissipate heat. Ensure the relay is securely attached to prevent relay "thermal" shutdown and relay damage, resulting in possible engine overheating. 1. Position relay and install a new rivet. 2. Connect electrical connector to relay. 3. Install closure panel and attaching screws. 4. Connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Front Heater Core: Description and Operation Front Heater Core The front heater core is mounted into the HVAC air distribution housing, located behind the instrument panel. The heater core is a heat exchanger made of rows of tubes and fins. The heater core tubes are attached to the heater core by a sealing plate and bolt. The heater core can be serviced without removing the air distribution housing from the vehicle. Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed through the heater core picks up the heat from the heater core fins. The blend-air door(s) allows control of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Front > Page 2586 Heater Core: Description and Operation Rear Rear Heater Core The rear heater core is located near the front of the rear HVAC housing, behind the right rear wheel house. It is a heat exchanger made of rows of tubes and fins. One end of the heater core is fitted with a molded plastic tank that includes the mounting provisions for the heater core and connections for the heater core inlet and outlet tubes. The rear heater core can be serviced without removing the rear HVAC housing from the vehicle. Engine coolant is circulated through underbody heater hoses to the rear heater core at all times. As the coolant flows through the rear heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The rear blend-air door allows control of the rear heater output air temperature by controlling how much of the air flowing through the rear HVAC housing is directed through the rear heater core. The rear heater core cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Page 2587 Heater Core: Testing and Inspection Successful completion of the rear heater performance check will confirm that the rear heater core is properly filled with engine coolant. If the check is not successful, either there is still air trapped in the rear heater core or the rear heater plumbing is restricted. This check should be performed with the vehicle in a shop where the ambient temperature is about 21° C (70° F). 1. Start the engine and allow it to idle until it warms up to normal operating temperature. 2. Adjust the A/C-heater controls so that the front heater is turned Off and the rear heater is set for full Heat with the rear blower motor at its highest speed setting. 3. Use an accurate test thermometer to measure the temperature of the air being discharged from the rear heater outlet located at the base of the right C-pillar. 4. Proper discharge air temperature readings should be from 57° to 63° C (135° to 145° F). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core: Service and Repair Front Removal - FRONT HEATER CORE WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. 1. Remove the silencer boot fasteners located around the base of the lower steering shaft from the dash panel so that it may be pushed aside. 2. Remove the brake lamp switch from its mounting bracket. 3. Disconnect the power brake booster input rod (push rod) from the pin on the brake pedal arm. 4. If equipped with power adjustable pedals, remove the adjustable pedal assembly. NOTE: Take the proper precautions to protect the carpeting below the heater core from spilled engine coolant and have absorbent toweling readily available to clean up any spills. 5. Remove the heater core tubes. 6. Remove the two screws that secure the heater core mounting plate to the HVAC air distribution housing. 7. If NOT equipped with power adjustable pedals, pull the accelerator pedal upward (Accelerator Pedal) and push the brake pedal downward (Brake Pedal) for clearance to remove the heater core from the air distribution housing. 8. Remove the heater core by carefully pulling it straight out of the side of the air distribution housing. Installation - FRONT HEATER CORE 1. If NOT equipped with power adjustable pedals, pull the accelerator pedal upward and push the brake pedal downward for clearance to install the heater core into the HVAC air distribution housing. 2. Install the heater core by carefully pushing it straight into the side of the air distribution housing. 3. Install the two screws that secure the heater core to the air distribution housing. Tighten the screws to 2 Nm (17 in. lbs.). 4. Install the heater core tubes. 5. If equipped with power adjustable pedals, install the adjustable pedal assembly 6. Connect the power brake booster input rod (push rod) to the pin on the brake pedal arm. 7. Install the brake lamp switch into its mounting bracket. 8. Install the silencer boot around the base of the lower steering shaft on the dash panel. 9. Reconnect the negative battery cable. 10. If the heater core is being replaced, flush the cooling system. 11. Refill the engine cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front > Page 2590 Heater Core: Service and Repair Front Heater Core Tubes REMOVAL WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. - REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Drain the engine cooling system. 2. Disconnect and isolate the negative battery cable. 3. Disconnect the heater hoses from the heater core tubes. 4. Remove the silencer from beneath the driver side end of the instrument panel. NOTE: Take the proper precautions to protect the carpeting below the heater core from spilled engine coolant and have absorbent toweling readily available to clean up any spills. Heater Core Tubes 5. Remove the screw that secures the heater core tube sealing plate to the heater core. 6. Push both heater core tubes simultaneously toward the dash panel and disengage the tubes from the heater core. 7. Install plugs in, or tape over the opened heater core tube fittings and both heater core ports. 8. Pull both heater core tubes simultaneously away from the distribution housing and rearward to disengage tubes from the dash panel seal and remove the tubes. INSTALLATION 1. Remove the plugs or tape from both heater core tube fittings and both heater core ports. 2. Position the heater core tubes and sealing plate to the dash panel, below the instrument panel. 3. Install both heater core tubes simultaneously through the dash panel seal. 4. Position both heater core tubes and the sealing plate simultaneously onto the heater core. NOTE: The heater core tubes each have a slot that must be indexed to a location tab within each of the heater core ports. Adjust the position of the tubes as required so that the sealing plate fits flush against the heater core supply and return ports, which indicates that the tubes are properly indexed. 5. Index both heater core tubes to the heater core ports. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front > Page 2591 6. Install the bolt that secures the heater core tube sealing plate to the heater core. Tighten the bolt to 3 N.m (27 in. lbs.). 7. Install the silencer under the driver side end of the instrument panel. 8. Connect the heater hoses to the heater hose tubes. 9. Reconnect the negative battery cable. 10. Refill the engine cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front > Page 2592 Heater Core: Service and Repair Rear Heater Core Filling WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. The rear heater core is positioned in the rear HVAC housing at a higher level than the radiator fill opening. Therefore, when the cooling system is drained and refilled, gravity will not totally refill the rear heater core. This may result in two problems: 1. Insufficient coolant level in the engine cooling system, which may result in engine overheating. 2. Air entrapped within the rear heater core, which may result in insufficient rear heater performance. There are two methods that may be employed to prevent these problems: 1. Pre-filling of the rear heater core. 2. Thermal cycling of the engine cooling system. Following are descriptions of both prevention methods, as well as a method to verify rear heater performance. PRE-FILLING NOTE: Take the proper precautions to protect the carpeting below the heater core from spilled engine coolant and have absorbent toweling readily available to clean up any spills. If the rear heater core or the rear HVAC housing have been removed from the vehicle for service, the rear heater core may be pre-filled with the proper engine coolant mixture prior to reconnecting the heater hoses to the heater core hose fittings. 1. The heater core should be installed in the rear HVAC housing, and the rear HVAC housing should be installed in the vehicle. Pre-Filling Heater Core - Typical 2. Insert the small end of an appropriate funnel into the upper hose fitting of the heater core. 3. Carefully pour the proper pre-mixed engine coolant solution into the rear heater core through a funnel until coolant begins to appear at the lower hose fitting of the rear heater core. 4. Connect the heater hoses to the rear heater core tubes. 5. Refill the engine cooling system. THERMAL CYCLING If the rear heater core was emptied and was not pre-filled, it will be necessary to thermal cycle the vehicle at least two times to ensure that the rear heater core is properly filled. 1. Refill the engine cooling system. 2. Start the engine and allow it to operate until the thermostat opens. 3. Turn the engine off and allow it to cool. 4. With the engine cold and not running, check and top off the engine coolant level as necessary. 5. Start the engine and allow it to operate until the thermostat opens again. 6. Turn the engine off and allow it to cool down again. 7. With the engine cold and not running, check and top off the engine coolant level as necessary. 8. Check the performance of the rear heater. Refer to REAR HEATER PERFORMANCE CHECK. See: Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front > Page 2593 Heater Core: Service and Repair Removal and Installation REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Drain the engine cooling system. 2. Remove the trim panels from the right inner quarter panel and the right D-pillar. 3. Remove the rear heater distribution duct. 4. Remove the screw that secures the back of the rear HVAC housing to the right D-pillar. 5. Remove the screw that secures the front of the rear HVAC housing to the right inner quarter panel. NOTE: Take the proper precautions to protect the carpeting below the heater core from spilled engine coolant and have absorbent toweling readily available to clean up any spills. 6. Disconnect the heater hoses from the rear heater core. Rear Heater Core 7. Install plugs in, or tape over the opened heater core fittings and both heater hoses. 8. Release the four retaining tabs that secure the rear heater core to the rear HVAC housing and remove the heater core. INSTALLATION NOTE: If the rear heater core or the rear HVAC housing have been removed from the vehicle for service, the rear heater core should be pre-filled with the proper engine coolant mixture prior to reconnecting the heater hoses to the heater core hose fittings. 1. Carefully position the rear heater core into the rear HVAC housing. 2. Using hand pressure, press firmly and evenly on the molded plastic tank of the rear heater core until the four retaining tabs that secure the rear heater core in the rear HVAC housing fully engage. 3. Remove the plugs or tape from the rear heater core fittings and both rear heater hoses. 4. Pre-fill the rear heater core. 5. Connect the rear heater hoses to the rear heater core. 6. Install the screw that secures the front of the rear HVAC housing to the right inner quarter panel. Tighten the screw to 11 N.m (97 in. lbs.). 7. Install the screw that secures the back of the rear HVAC housing to the right D-pillar. Tighten the screw to 11 N.m (97 in. lbs.). 8. Install the rear distribution duct. 9. Install the trim panels onto the right inner quarter panel and the right D-pillar. 10. If the heater core is being replaced, flush the cooling system. 11. Refill the engine cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Recalls for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement Technical Service Bulletin # F06 Date: 060401 Campaign - Underbody Heater Hose Replacement April 2006 Dealer Service Instructions for: Customer Satisfaction Notification F06 Underbody Heater Hoses Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 05-028 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2005 (RS) Dodge Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles equipped with rear Heater/Air Conditioning (sales code HBB) and Stow-n-Go seats (sales code CYC) or Stow-N-Go floor pan (sales code CYY or CYV). IMPORTANT: The above vehicles located in the "salt belt" are involved in Customer Satisfaction Notification F01 (Rear A/C Heater tube Corrosion) and therefore have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The underbody heater hoses on about 141,000 of the above vehicles may leak coolant at the heater tube crimps. This may result in the engine overheating. Engine damage can occur if an overheated engine continues to be driven. Repair The underbody heater hoses for the rear heater must be replaced. Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Recalls for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 2602 Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the hood. 2. Lower the spare tire using the crank handle inside the vehicle (approximately 10 turns). 3. Using pinch-off pliers, clamp off the heater hoses in the engine compartment that connect the rear heater tubes to the engine cooling system. 4. Lift the vehicle on an appropriate hoist. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Recalls for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 2603 5. Using a cut off wheel, grind a slot into the heater tube aluminum crimp band on the two rear heater hoses (Figure 1). CAUTION: Do not allow the grinding wheel to touch the aluminum heater tubes. 6. Remove the aluminum crimp band from the hose using expanding snap-ring pliers (Snap-on SRP5A or equivalent) (Figure 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Recalls for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 2604 7. Slide the spring clamps off of the heater core quick-connect fittings located on the rear heater core tubes (Figure 3). 8. Carefully remove both old heater hoses from the heater tubes. CAUTION: Residual coolant will come out of the hoses and tubes when the heater hoses are removed. Use an appropriate container to catch the coolant. 9. Remove and save the spring clamps on the old hoses. Then discard the old hoses. 10. Install two spring clamps onto each heater tube. 11. Using the short hoses supplied in the kit, install the new heater hoses onto the heater hose tubes and the heater core tube quick connects. 12. Place the spring clamps at each end of the new heater hose. NOTE: The wings of the spring clamps should be pointed downward. 13. Remove the spare tire heat shields to gain access to the front set of heater hoses. 14. Using a cut off wheel, grind a slot into the heater tube aluminum crimp band on the two heater hoses (Figure 4). CAUTION: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Recalls for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 2605 Do not allow the grinding wheel to touch the aluminum heater tubes. 15. Remove the aluminum crimp band from the hose using expanding snap-ring pliers (Snap-on SRP5A or equivalent) (Figure 2). 16. Slide the spring clamps off the heater hoses (Figure 3). 17. Remove the heater hoses from the vehicle. 18. Remove and save the spring clamps on the old hoses. Then discard the old hoses 19. Install two spring clamps onto each heater tube. 20. Using the long hoses supplied in the kit, install the new heater hoses onto the heater hose tubes. 21. Place the spring clamps at each end of the new heater hose. NOTE: The wings of the spring clamp should be pointed downward. 22. Install the tire heat shields. 23. Lower the vehicle. 24. Remove the pinch-off pliers on the heater hoses in the engine compartment. 25. Raise the spare tire into position using the crank handle inside the vehicle. 26. Check the engine coolant level and add coolant as required. 27. Start the engine and ensure that the new heater hoses do not leak. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Recalls for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 2606 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement Technical Service Bulletin # F06 Date: 060401 Campaign - Underbody Heater Hose Replacement April 2006 Dealer Service Instructions for: Customer Satisfaction Notification F06 Underbody Heater Hoses Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 05-028 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2005 (RS) Dodge Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles equipped with rear Heater/Air Conditioning (sales code HBB) and Stow-n-Go seats (sales code CYC) or Stow-N-Go floor pan (sales code CYY or CYV). IMPORTANT: The above vehicles located in the "salt belt" are involved in Customer Satisfaction Notification F01 (Rear A/C Heater tube Corrosion) and therefore have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The underbody heater hoses on about 141,000 of the above vehicles may leak coolant at the heater tube crimps. This may result in the engine overheating. Engine damage can occur if an overheated engine continues to be driven. Repair The underbody heater hoses for the rear heater must be replaced. Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 2612 Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the hood. 2. Lower the spare tire using the crank handle inside the vehicle (approximately 10 turns). 3. Using pinch-off pliers, clamp off the heater hoses in the engine compartment that connect the rear heater tubes to the engine cooling system. 4. Lift the vehicle on an appropriate hoist. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 2613 5. Using a cut off wheel, grind a slot into the heater tube aluminum crimp band on the two rear heater hoses (Figure 1). CAUTION: Do not allow the grinding wheel to touch the aluminum heater tubes. 6. Remove the aluminum crimp band from the hose using expanding snap-ring pliers (Snap-on SRP5A or equivalent) (Figure 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 2614 7. Slide the spring clamps off of the heater core quick-connect fittings located on the rear heater core tubes (Figure 3). 8. Carefully remove both old heater hoses from the heater tubes. CAUTION: Residual coolant will come out of the hoses and tubes when the heater hoses are removed. Use an appropriate container to catch the coolant. 9. Remove and save the spring clamps on the old hoses. Then discard the old hoses. 10. Install two spring clamps onto each heater tube. 11. Using the short hoses supplied in the kit, install the new heater hoses onto the heater hose tubes and the heater core tube quick connects. 12. Place the spring clamps at each end of the new heater hose. NOTE: The wings of the spring clamps should be pointed downward. 13. Remove the spare tire heat shields to gain access to the front set of heater hoses. 14. Using a cut off wheel, grind a slot into the heater tube aluminum crimp band on the two heater hoses (Figure 4). CAUTION: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 2615 Do not allow the grinding wheel to touch the aluminum heater tubes. 15. Remove the aluminum crimp band from the hose using expanding snap-ring pliers (Snap-on SRP5A or equivalent) (Figure 2). 16. Slide the spring clamps off the heater hoses (Figure 3). 17. Remove the heater hoses from the vehicle. 18. Remove and save the spring clamps on the old hoses. Then discard the old hoses 19. Install two spring clamps onto each heater tube. 20. Using the long hoses supplied in the kit, install the new heater hoses onto the heater hose tubes. 21. Place the spring clamps at each end of the new heater hose. NOTE: The wings of the spring clamp should be pointed downward. 22. Install the tire heat shields. 23. Lower the vehicle. 24. Remove the pinch-off pliers on the heater hoses in the engine compartment. 25. Raise the spare tire into position using the crank handle inside the vehicle. 26. Check the engine coolant level and add coolant as required. 27. Start the engine and ensure that the new heater hoses do not leak. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 2616 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front Heater Hose: Service and Repair Front Heater Inlet Hose REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The heater inlet hose is constructed from formed steel tubing and rubber hoses. Depending on application, the ends are secured to the heater core, engine oil cooler or the engine by spring tension clamps. 1. Drain the engine cooling system. Heater Inlet Hose - 2.4L Shown, 2.5L Typical Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front > Page 2619 Heater Inlet Hose - 3.3L/3.8L W/O Rear Heater Heater Inlet Hose - 3.3L/3.8L With Rear Heater 2. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes/heater core, causing an engine coolant leak. 3. Disconnect each hose end by carefully twisting the hose back and forth on the tube or nipple, while gently pulling it away from the end of the tube or nipple. NOTE: Replacement of the heater inlet hoses will be required if the hose ends are cut for removal. 4. If necessary, carefully cut the hose end and peel the hose off of the tube or nipple. INSTALLATION 1. Using spring tension clamp pliers, compress and slide each clamp away from the end of the hose being installed. 2. Install each hose by carefully twisting the hose back and forth while gently pushing it onto the tube or nipple end. 3. Using spring tension clamp pliers, compress and slide the clamps onto each end of the hose being installed. 4. Refill the engine cooling system. Heater Return Hose REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The heater return tube is constructed from formed steel tubing and rubber hoses. Depending on application, the ends are secured to the heater core, engine oil cooler or the engine by spring tension clamps. 1. Drain the engine cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front > Page 2620 Heater Return Hose - 2.4L Shown, 2.5L Typical Heater Return Hose - 3.3L/3.8L W/O Rear Heater Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front > Page 2621 Heater Hoses - 3.3/3.8L With Rear Heater 2. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes/heater core, causing an engine coolant leak. 3. Disconnect each hose end by carefully twisting the hose back and forth on the tube or nipple, while gently pulling it away from the end of the tube or nipple. NOTE: Replacement of the heater return hoses will be required if the hose ends are cut for removal. 4. If necessary, carefully cut the hose end and peel the hose off of the tube or nipple. INSTALLATION 1. Using spring tension clamp pliers, compress and slide the clamp away from the end of the heater return hose. 2. Install each hose end by carefully twisting the hose back and forth while gently pushing it onto the tube. 3. Using spring tension clamp pliers, compress and slide the clamps onto each end of the heater return hose. 4. Refill the engine cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Front > Page 2622 Heater Hose: Service and Repair Rear Heater Hoses REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Drain the engine cooling system. 2. Raise and support the vehicle. 3. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes, causing an engine coolant leak. Underbody Heater Hose Connections - Front 4. Disconnect the front underbody heater inlet and return hose by carefully twisting the hoses back and forth on the underbody tubes, while gently pulling them away from the end of the tubes. 5. If necessary, carefully cut the hose ends and peel the hoses off of the tubes. NOTE: Replacement of the heater hoses will be required if the hose ends are cut for removal. INSTALLATION 1. Install the front underbody heater inlet and return hoses by carefully twisting the hoses back and forth on the underbody tubes, while gently pushing them onto the end of the tubes. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes, causing an engine coolant leak. 2. Using spring tension clamp pliers, compress and slide the clamps that secure each end of the heater hose over the tubes. Release the clamp when it is over the tube. 3. Lower the vehicle. 4. Refill the engine cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge Diagnosis Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair REMOVAL CAUTION: Use of pliers on draincock is not recommended. Damage may occur to radiator or draincock. NOTE: It is not necessary to remove draincock during a routine coolant drain. 1. Drain the cooling system. 2. Open the draincock by turning it counterclockwise until it stops. 3. Turn the draincock back (clockwise) 1/8 turn. Fig.16 4. Pull the draincock from the radiator tank. INSTALLATION 1. Align draincock stem to radiator tank opening. 2. Push draincock into the radiator tank opening. 3. Tighten the draincock by turning clockwise until it stops. 4. Fill the cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation Radiator Cap: Description and Operation DESCRIPTION Fig.17 The cooling system pressure cap is located on the radiator. The cap construction includes; stainless steel swivel top, rubber seals, and retainer, main spring, and a spring loaded valve. OPERATION The cooling system is equipped with a pressure cap that releases excessive pressure; maintaining a range of 97 - 124 kPa (14 - 18 psi). The cooling system will operate at higher than atmospheric pressure. The higher pressure raises the coolant boiling point thus, allowing increased radiator cooling capacity. There is also a vent valve in the center of the cap. This valve also opens when coolant is cooling and contracting, allowing the coolant to return to cooling system from coolant reserve system tank by vacuum through a connecting hose. If valve is stuck shut, or the coolant recovery hose is pinched, the radiator hoses will be collapsed on cool down. Clean the vent valve and inspect coolant recovery hose routing, to ensure proper sealing when boiling point is reached. The gasket in the cap seals the filler neck, so that vacuum can be maintained, allowing coolant to be drawn back into the radiator from the reserve tank. If the gasket is dirty or damaged, a vacuum may not be achieved, resulting is loss of coolant and eventual overheating due to low coolant level in radiator and engine. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Radiator Cap: Initial Inspection and Diagnostic Overview INSPECTION Fig.20 Hold the cap in your hand, top side up. The vent valve at the bottom of the cap should open. If the rubber gasket has swollen, preventing the valve from opening, replace the cap. Hold the cleaned cap in your hand, upside down. If any light can be seen between vent valve and the rubber gasket, replace the cap. Do not use a replacement cap that has a spring to hold the vent shut. A replacement cap must be of the type designed for coolant reserve systems. This design ensures coolant return to the radiator. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2636 Radiator Cap: Component Tests and General Diagnostics Cooling System Pressure Relief Testing RADIATOR CAP TO FILLER NECK SEAL Fig.19 The pressure cap upper gasket (seal) pressure relief can be checked by removing the overflow hose at the radiator filler neck nipple. Attach the Radiator Pressure Tool to the filler neck nipple and pump air into the radiator. Pressure cap upper gasket should relieve at 69 - 124 kPa (10 - 18 psi) and hold pressure at 55 kPa (8 psi) minimum. WARNING: THE WARNING WORDS "DO NOT OPEN HOT" ON THE RADIATOR PRESSURE CAP IS A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, THE RADIATOR CAP SHOULD NOT BE REMOVED WHILE THE SYSTEM IS HOT OR UNDER PRESSURE. There is no need to remove the radiator cap at any time except for the following purposes: 1. Check and adjust coolant freeze point. 2. Refill system with new coolant. 3. Conducting service procedures. 4. Checking for vacuum leaks. WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE REMOVING CAP. THEN PLACE A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN ROTATE COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING COOLANT AND STEAM INTO THE CRS TANK AND PRESSURE DROPS PUSH DOWN AND REMOVE THE CAP COMPLETELY. SQUEEZING THE RADIATOR INLET HOSE WITH A SHOP TOWEL (TO CHECK PRESSURE) BEFORE AND AFTER TURNING TO THE FIRST STOP IS RECOMMENDED. Radiator Cap Testing COOLING SYSTEM PRESSURE CAP TESTING Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2637 Fig.18 Dip the pressure cap in water. Clean any deposits off the vent valve or its seat and apply cap to end of the Pressure Cap Test Adapter that is included with the Cooling System Tester 7700. Working the plunger, bring the pressure to 104 kPa (15 psi) on the gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi), replace the pressure cap. CAUTION: The Cooling System Tester Tool is very sensitive to small air leaks that will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to the tool. Turn tool upside down and recheck pressure cap to confirm that cap is bad. If the pressure cap tests properly while positioned on Cooling System Tester, but will not hold pressure or vacuum when positioned on the filler neck. Inspect the filler neck and cap top gasket for irregularities that may prevent the cap from sealing properly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Page 2638 Radiator Cap: Service and Repair CLEANING Use only a mild soap to clean the pressure cap. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor Relay: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2645 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2646 Figure 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2647 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2648 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2649 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2650 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2651 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2652 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2653 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2654 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2655 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2656 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2657 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2658 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2659 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2660 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2661 Radiator Cooling Fan Motor Relay: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and an Electrostatic Discharge Symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2662 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2663 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2664 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2665 Radiator Fan Realy (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2666 8w-42-20 (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 2667 Radiator Cooling Fan Motor Relay: Description and Operation DESCRIPTION Fig.22 The radiator fan relay is a solid state type and is located on the front bumper reinforcement. OPERATION The solid state radiator fan relay is controlled by the Powertrain Control Module (PCM) by way of a Pulse Width Modulated (PWM) signal. The relay control circuit supplies a 12 volt signal to the PCM. The PCM then pulses the ground circuit to achieve fan on time. The relay provides a voltage to the fan motors which is proportional to the pulse width it receives from the PCM. The duty cycle ranges from 30% for low speed operation, then ramps-up to 100% for high speed operation. This fan control system provides infinitely variable fan speeds, allowing for improved fan noise, A/C performance, better engine cooling, and additional vehicle power. To control operation of the relay, the PCM looks at inputs from: ^ Engine coolant temperature ^ A/C pressure transducer ^ Ambient temperature from the body controller ^ Vehicle speed ^ Transmission oil temperature The PCM uses these inputs to determine when the fan should operate and at what speed. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 2668 Radiator Cooling Fan Motor Relay: Testing and Inspection Test 1 - 3 SYMPTOM CHECKING RADIATOR FAN RELAY OUTPUT POSSIBLE CAUSES - Radiator Fan Relay Operation - Ground Circuit Open - Radiator Fan Relay Output Circuit - Radiator Fan Assembly Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Page 2669 Radiator Cooling Fan Motor Relay: Service and Repair REMOVAL Fig.22 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Remove the radiator crossmember to front fascia closure panel. 4. Disconnect the relay electrical connector. 5. Remove the rivet attaching the relay to the front bumper beam. 6. Remove the relay. INSTALLATION CAUTION: The relay mounting location is designed to dissipate heat. Ensure the relay is securely attached to prevent relay "thermal" shutdown and relay damage, resulting in possible engine overheating. 1. Position relay and install a new rivet. 2. Connect electrical connector to relay. 3. Install closure panel and attaching screws. 4. Connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Diagrams A/C Pressure Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge Diagnosis Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation Thermostat: Description and Operation DESCRIPTION Fig.8 Fig.10 The engine cooling thermostats are a wax pellet driven, reverse poppet choke type. The thermostat is operated by a wax filled container (pellet), which is sealed. When heated coolant reaches a predetermined temperature, the wax expands enough to overcome the closing spring and water pump pressure, which forces the valve to open. The thermostat is mounted in a housing on the coolant outlet of the engine or. OPERATION The engine cooling thermostat is a wax pellet driven, reverse poppet choke type. The thermostat is designed to provide the fastest warm up possible by preventing leakage through it and to guarantee a minimum engine operating temperature of 88 - 93 °C (192 - 199 °F). The thermostat also will automatically reach wide open so it will not restrict flow to the radiator as temperature of the coolant rises in hot weather to around 104 °C (220 °F). Above this temperature the coolant temperature is controlled by the radiator, fan, and ambient temperature, not the thermostat. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Page 2684 Thermostat: Testing and Inspection ENGINE COOLANT THERMOSTAT The thermostat is operated by a wax filled chamber (pellet), which is sealed. When heated coolant reaches a predetermined temperature the wax pellet expands enough to overcome the closing spring and water pump pressure, which forces the valve to open. Coolant leakage into the pellet will cause a thermostat to fail open. Do not attempt to free up a thermostat with a screwdriver. Thermostat diagnostics is included in Powertrain Control Module'S (PCM) programming for on-board diagnosis. The Malfunction Indicator Light (MIL) will illuminate and a Diagnostic Trouble Code (DTC) will be set when an "open too soon" condition occurs. Do not change a thermostat for lack of heater performance or temperature gauge position, unless a DTC is present. Thermostat failing shut is the normal long term mode of failure, and normally, only on high mileage vehicles. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Page 2685 Thermostat: Service and Repair REMOVAL 1. Drain cooling system down below the thermostat level. Fig.9 2. Remove radiator upper hose from coolant outlet connector. Fig.10 3. Remove coolant outlet connector bolts and connector. 4. Remove thermostat from outlet connector. 5. Discard gasket and clean both gasket sealing surfaces. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Page 2686 Fig.11 1. To ensure proper seating of replacement thermostat, carefully remove the bulged metal from the wall of the outlet connector recess that was created during the staking procedure that held the OEM thermostat in place. It is not necessary to restake the replacement thermostat into the connector. Fig.12 2. Position thermostat to coolant outlet connector. Align the two locating notches on thermostat to the connector. This position will ensure proper location of the thermostat air bleed. 3. Position a new gasket over the thermostat and connector making sure thermostat is in proper position and in the recess provided. 4. Install thermostat and connector assembly to the intake manifold. Tighten bolts to 28 Nm (250 in. lbs.). 5. Install the radiator upper hose to coolant outlet connector. 6. Refill the cooling system to the proper level. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Drive Pulley, Water Pump > Component Information > Specifications Drive Pulley: Specifications Water Pump Pulley Bolts ..................................................................................................................... ................................................. 28 Nm (250 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Specifications Exhaust Crossover Pipe: Specifications Cross-over Pipe Fastener .................................................................................................................... ..................................................... 41 Nm (30 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Specifications > Page 2695 Exhaust Crossover Pipe: Service and Repair REMOVAL 1. Disconnect negative cable from battery. Fig.6 2. Remove the fasteners attaching the left bank manifold connection to cross over pipe. 3. Raise vehicle and remove the left front wheel. 4. Access the lower right bank pipe connection fastener through the left front wheel opening using a long ratchet extension. Loosen and remove the lower fastener. 5. Remove the upper right bank pipe connection fastener by accessing though the catalytic converter floor pan tunnel. 6. Lower the vehicle. 7. Remove the cross-over pipe. 8. Remove gaskets and discard. INSTALLATION 1. Position cross-over pipe to the manifold connections. 2. Position new gasket on left bank (front) pipe connection and loosely install fasteners. 3. Raise the vehicle. 4. Position new gasket on the right bank pipe connection and install fasteners. 5. Tighten right bank upper fastener to 41 Nm (30 ft. lbs.). 6. Tighten right bank lower fastener to 41 Nm (30 ft. lbs.) using a long ratchet extension accessing through the left wheel opening. 7. Install the left front wheel and lower vehicle. 8. Tighten the left bank pipe connection fasteners to 41 Nm (30 ft. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold Bolts 200 in.lb Exhaust Crossover Pipe Bolts 30 ft.lb Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 2699 Exhaust Manifold: Description and Operation DESCRIPTION The exhaust manifolds are log type and made of Hi-Sil-Moly (high temperature resistant) nodular cast iron. The exhaust manifolds are attached directly to the cylinder heads and a cross-over pipe connects the two manifolds. OPERATION The exhaust manifolds collects the exhaust gases exiting the combustion chambers. It then channels the exhaust gases to the exhaust pipe that is attached to the rear (right side) manifold. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - Left Exhaust Manifold: Service and Repair Exhaust Manifold - Left REMOVAL 1. Disconnect battery negative cable. Fig.135 2. Remove bolts attaching crossover pipe to exhaust manifold. 3. Disconnect left cylinder bank spark plug wires. Fig.136 4. Remove heat shield attaching bolts. 5. Remove bolts attaching exhaust manifold to cylinder head. 6. Remove the exhaust manifold. 7. Inspect and clean manifold. CLEANING 1. Discard gasket (if equipped) and clean all surfaces of manifold and cylinder head. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - Left > Page 2702 INSPECTION Fig.137 Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting surface and exhaust crossover mounting surface with a straightedge and thickness gauge. Manifold surface flatness limits should not exceed 1.0 mm (0.039 in.). INSTALLATION 1. Position exhaust manifold on cylinder head. Install bolts to center runner (cylinder # 4) and initial tighten to 2.8 Nm (25 in. lbs.). 2. Using a new gasket, attach crossover pipe to exhaust manifold and tighten bolts to 41 Nm (30 ft. lbs.). NOTE: Inspect crossover pipe fasteners for damage from heat and corrosion. The cross-over bolts are made of a special stainless steel alloy. If replacement is required, OEM bolts are highly recommended. 3. Position heat shield on manifold. 4. Install the remaining manifold attaching bolts. Tighten all bolts to 23 Nm (200 in. lbs.). 5. Install and tighten heat shield attaching nut to 12 Nm (105 in. lbs.). 6. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - Left > Page 2703 Exhaust Manifold: Service and Repair Exhaust Manifold - Right EXHAUST MANIFOLD RIGHT REMOVAL 1. Disconnect battery negative cable. 2. Remove the wiper module. 3. Disconnect spark plug wires. Fig.130 4. Remove bolts fastening crossover pipe to exhaust manifold. Fig.133 5. Disconnect and remove the upstream oxygen sensor. 6. Remove the heat shield attaching screws. 7. Remove the upper heat shield. 8. Raise vehicle on hoist and remove drive belt shield. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - Left > Page 2704 Fig.131 Fig.132 9. Loosen the power steering pump support strut lower bolt. 10. Disconnect downstream oxygen sensor connector. 11. Disconnect catalytic converter pipe from exhaust manifold. 12. Lower vehicle and remove the power steering pump support strut upper bolt. 13. Remove bolts attaching exhaust manifold to cylinder head and remove manifold. 14. Inspect and clean manifold. CLEANING 1. Discard gasket (if equipped) and clean all surfaces of manifold and cylinder head. INSPECTION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold - Left > Page 2705 Fig.134 Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting surface and exhaust crossover mounting surface with a straightedge and thickness gauge. Manifold surface flatness limits should not exceed 1.0 mm (0.039 in.). INSTALLATION 1. Position exhaust manifold on cylinder head and install bolts to center runner (cylinder # 3) and initial tighten to 2.8 Nm (25 in. lbs.) 2. Using a new gasket, attach crossover pipe to exhaust manifold and tighten bolts to 41 Nm (30 ft. lbs.). NOTE: Inspect crossover pipe fasteners for damage from heat and corrosion. The cross-over bolts are made of a special stainless steel alloy. If replacement is required, OEM bolts are highly recommended. 3. Install the remaining manifold attaching bolts. Tighten all bolts to 23 Nm (200 in. lbs.). 4. Position the power steering pump support strut and install upper bolt. 5. Install heat shield and attaching screws. 6. Install and connect upstream oxygen sensor. 7. Raise the vehicle. 8. Attach catalytic converter pipe to exhaust manifold using new gasket and tighten bolts to 37 Nm (27 ft. lbs.). 9. Connect downstream oxygen sensor connector. 10. Tighten the power steering pump support strut lower bolt. 11. Install the belt splash shield and lower the vehicle. 12. Install the wiper module. 13. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Heat Shield (Muffler) Fastener ............................................................................................................ ................................................... 2.6 Nm (23 in. lbs.) Heat Shield (Toe Board) Fastener .......................................................................................................................................................... 2.6 Nm (23 in. lbs.) Heat Shield (Resonator Pipe) Fastener ................................................................................................................................................... 2.6 Nm (23 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 2709 Heat Shield: Description and Operation DESCRIPTION Fig.7 Fig.8 Fig.9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 2710 The exhaust system heat shields,, or are attached to the under body of the vehicle. On vehicles equipped with All Wheel Dive (AWD), an additional heat shield is mounted to the catalytic converter. OPERATION Heat shields are needed to protect both the vehicle and the environment from the high temperatures developed near the catalytic converter. Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan heat shields on cars so equipped. Light over spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the heat shields resulting in excessive floor pan temperatures and objectionable fumes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 2711 Heat Shield: Service and Repair REMOVAL Fig.7 Fig.8 Fig.9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 2712 1. Raise vehicle on hoist. 2. Remove fasteners attaching applicable heat shield,,. 3. Remove heat shield(s). INSTALLATION 1. Position heat shield(s) to underbody. 2. Install heat shield fasteners and tighten to 2.6 Nm (23 in. lbs.),,. 3. Lower vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair Muffler: Service and Repair REMOVAL 1. Raise vehicle on a body contact type hoist. NOTE: To provide removal clearance between muffler/resonator pipe and rear axle parts, the rear suspension must be relieved of all body weight. 2. Apply a penetrating oil to clamp nuts of component requiring removal. CAUTION: When servicing the exhaust system, care must be exercised not to dent or bend the bellows of the flex-joint. Should this occur, the flex-joint will eventually fail, requiring replacement of the catalytic converter. 3. Disconnect the right side axle half shaft from the rear differential module (AWD equipped only). Fig.10 4. Loosen the band clamp at the muffler to converter pipe connection. 5. Remove the exhaust hangers to body screws. 6. Separate muffler pipe from converter pipe. 7. Remove muffler/resonator assembly by moving assembly forward and guiding the resonator through the rear axle to body opening. 8. Clean ends of pipes or muffler to assure mating of all parts. Discard broken or worn insulators, rusted clamps, supports and attaching parts. When replacement is required on any component of the exhaust system, it is important that original equipment parts (or equivalent) be used for the following conditions: Ensure proper alignment with other components in the system. - Provide acceptable exhaust noise levels. - Provide proper exhaust system back pressure for maintaining emission and performance levels. INSTALLATION 1. Install the muffler/resonator assembly by guiding resonator between the rear axle and body. 2. Connect the muffler pipe to the converter pipe but do not tighten band clamp. 3. Position hangers to body and install screws starting at the resonator working forward. Tighten hanger screws to 28 Nm (250 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Page 2716 Fig.11 4. Insert muffler pipe into catalytic converter pipe until the hangers are positioned as shown in CAUTION: Band clamps should never be tightened such that the two sides of the clamps are bottomed out against the center hourglass shaped center block. Once this occurs, the clamp band has been stretched and has lost its clamping force and must be replaced. To replace the band clamp; remove the nut and peel back the ends of the clamp until spot weld breaks. Clean remaining spot weld from the pipe using a file or grinder until surface is smooth. NOTE: Maintain proper clamp orientation when replacing with new clamp. Fig.12 5. Tighten the band clamp to 55 Nm (40 ft. lbs.). 6. Connect the right side half shaft to the rear differential module (AWD equipped only). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set Body Control Module: Customer Interest Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set NUMBER: 08-028-05 GROUP: Electrical DATE: May 28, 2005 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD JULY, 2005. SUBJECT: Flash: MIL Illumination, Remote Keyless Entry (RKE) Inoperative OVERVIEW: This bulletin involves reprogramming the Body Control Module (BCM) with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to CS vehicles built on or before May 7, 2005 (MDH 0507XX) and RS vehicles, built on or between July 26, 2004 (MDH 0726XX) through and including May 7, 2005 (MDH 0507XX), with a 4-connector BCM. SYMPTOM/CONDITION: ^ MIL Illumination ^ RKE inoperative ^ PCI Internal Fault DTC in BCM DIAGNOSIS: 1. With the ignition switch in the "RUN" position, determine the original software part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R)" standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 2728 g. Record the "Software part # " on the repair order for later reference. h. Check DTC's 2. If the Symptom/Condition is present, use the following table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "BCM part # ", recorded in "Diagnosis Step # 1, in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 4. Select the flash file. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 2729 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm Body Control Module: Customer Interest Electrical - Locks Inoperative/Liftgate Triggers Alarm NUMBER: 08-040-04 GROUP: Electrical DATE: December 9, 2004 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD FEBRUARY, 2005. SUBJECT: Flash: Driver And Passenger Power Door Lock Switches Inoperative And Opening the Liftgate Triggers The Theft Alarm OVERVIEW: This bulletin involves selectively erasing and reprogramming the Body Control Module (BCM) with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to 2005 vehicles equipped with Power Locks only (sales code JPB) and 2004 2005 vehicles equipped with Power Locks, Power Liftgate, and Security Alarm (sales codes JPB, JRC and LSA respectively). SYMPTOM/CONDITION: The vehicle operator may describe: ^ The alarm sounds erroneously when opening the power liftgate using the key fob while the Vehicle Theft Alarm (VTA) is armed. ^ The driver's and/or passenger's door lock switches are inoperative. The technician may find "Left Unlock Output Failure" and/or "Right Unlock Output Failure" Diagnostic Trouble Codes (DTC's) in the BCM. DIAGNOSIS: 1. Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. With the ignition switch in the "RUN" position, determine the original part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" g. Record the "Software part # " on the repair order for later reference. h. Check DTC's Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm > Page 2734 3. If the vehicle operator describes or experiences the Symptom/Condition, use the table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "Software part # " recorded during "Diagnosis" in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 4. Select the calibration. 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm > Page 2735 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition to the "Run" position (engine not running). 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. 13. Verify that the problem cannot be repeated by cycling the ignition switch OFF/ON and actuating both door lock switches a few times. If any door lock failure still persists then further diagnosis is necessary. Verify the BCM "Software p/n" was updated to the new software p/n using Diagnosis Step # 2. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, PCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set Body Control Module: All Technical Service Bulletins Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set NUMBER: 08-028-05 GROUP: Electrical DATE: May 28, 2005 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD JULY, 2005. SUBJECT: Flash: MIL Illumination, Remote Keyless Entry (RKE) Inoperative OVERVIEW: This bulletin involves reprogramming the Body Control Module (BCM) with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to CS vehicles built on or before May 7, 2005 (MDH 0507XX) and RS vehicles, built on or between July 26, 2004 (MDH 0726XX) through and including May 7, 2005 (MDH 0507XX), with a 4-connector BCM. SYMPTOM/CONDITION: ^ MIL Illumination ^ RKE inoperative ^ PCI Internal Fault DTC in BCM DIAGNOSIS: 1. With the ignition switch in the "RUN" position, determine the original software part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R)" standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 2741 g. Record the "Software part # " on the repair order for later reference. h. Check DTC's 2. If the Symptom/Condition is present, use the following table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "BCM part # ", recorded in "Diagnosis Step # 1, in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 4. Select the flash file. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 2742 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm Body Control Module: All Technical Service Bulletins Electrical - Locks Inoperative/Liftgate Triggers Alarm NUMBER: 08-040-04 GROUP: Electrical DATE: December 9, 2004 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD FEBRUARY, 2005. SUBJECT: Flash: Driver And Passenger Power Door Lock Switches Inoperative And Opening the Liftgate Triggers The Theft Alarm OVERVIEW: This bulletin involves selectively erasing and reprogramming the Body Control Module (BCM) with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to 2005 vehicles equipped with Power Locks only (sales code JPB) and 2004 2005 vehicles equipped with Power Locks, Power Liftgate, and Security Alarm (sales codes JPB, JRC and LSA respectively). SYMPTOM/CONDITION: The vehicle operator may describe: ^ The alarm sounds erroneously when opening the power liftgate using the key fob while the Vehicle Theft Alarm (VTA) is armed. ^ The driver's and/or passenger's door lock switches are inoperative. The technician may find "Left Unlock Output Failure" and/or "Right Unlock Output Failure" Diagnostic Trouble Codes (DTC's) in the BCM. DIAGNOSIS: 1. Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. With the ignition switch in the "RUN" position, determine the original part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" g. Record the "Software part # " on the repair order for later reference. h. Check DTC's Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm > Page 2747 3. If the vehicle operator describes or experiences the Symptom/Condition, use the table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "Software part # " recorded during "Diagnosis" in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 4. Select the calibration. 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm > Page 2748 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition to the "Run" position (engine not running). 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. 13. Verify that the problem cannot be repeated by cycling the ignition switch OFF/ON and actuating both door lock switches a few times. If any door lock failure still persists then further diagnosis is necessary. Verify the BCM "Software p/n" was updated to the new software p/n using Diagnosis Step # 2. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, PCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 2751 Body Control Module: Connector Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 2752 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 2753 Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2756 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2757 Figure 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2758 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2759 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2760 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2761 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2762 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2763 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2764 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2765 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2766 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2767 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2768 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2769 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2770 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2771 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2772 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and an Electrostatic Discharge Symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2773 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2774 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2775 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2776 Body Control Module: Connector Views Body Control Module C1 Body Control Module C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2777 Body Control Module C3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2778 Body Control Module C4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2779 Body Control Module C5 (early Build) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2780 Body Control Module: Electrical Diagrams Non-memory Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2781 Memory Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2782 Occupant Restraint Controller - Highline Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2783 Occupant Restraint Controller - Lowline Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2784 Occupant Classification System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2785 Premium Audio System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2786 Base Audio System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2787 CD Changer DVD/CD Changer Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2788 Remote Radio Controls Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2789 Front ATC - LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2790 Front ATC - RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2791 Rear ATC - Three Zone Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2792 Diesel Cabin Heater Assist (DCHA) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2793 Communication Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2794 PCM Communication - NGC ECM And Cabin Heater Assist Communication - Diesel Only Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2795 Door Ajar System With Power Sliding Doors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2796 Door Ajar System Without Power Sliding Doors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2797 Exterior Lighting Horn System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2798 Ignition Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2799 Integrated Power Module/body Control Module Power And Grounds Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2800 Instrument Cluster - Base Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2801 Instrument Cluster And Message Center (export, LHD) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2802 Instrument Cluster And Message Center (export,RHD) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2803 Interior Lighting Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2804 Base Manual Temperature Control System, LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2805 Base Manual Temperature Control System. RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2806 Dual-zone And Three Zone(front) Manual Temperature Control System, LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2807 Dual-zone Zone(front) Manual Temperature Control System, RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2808 Three Zone Rear Manual Temperature Control System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2809 Front Blower Motor - RS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2810 Front Blower Motor - RG Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2811 Rear Blower Motor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2812 Memory System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2813 Overhead Console Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2814 Park Assist Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2815 Power Door Looks/RKE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2816 LHD (export Only) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2817 RHD (export Only) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2818 Power Liftgate System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2819 Lift Power Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2820 Right Power Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2821 Power Sliding Door And Liftgate Switches Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2822 Rear Defog/Heated Mirror Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2823 Hands Free Phone - With CD Changer Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2824 Hands Free Phone - With CD/DVD Changer Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2825 Vehicle Theft Security System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2826 Thatcam Alarm System (export Only) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2827 Wipers - Front And Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2828 A/C - Lef Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2829 Le - Tr 8W-45-2 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2830 8w-45-2 Next Diagram See: 8W-45-3 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-3 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2831 8w-45-3 Next Diagram See: 8W-45-4 Previous Diagram See: 8W-45-2 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2832 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-4 Next Diagram See: 8W-45-5 Previous Diagram See: 8W-45-3 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2833 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-5 Next Diagram See: 8W-45-6 Previous Diagram See: 8W-45-4 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2834 8W-45-6 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-6 Next Diagram See: 8W-45-7 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2835 Previous Diagram See: 8W-45-5 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-7 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2836 8w-45-7 Next Diagram See: 8W-45-8 Previous Diagram See: 8W-45-6 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-8 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2837 8w-45-8 Next Diagram See: 8W-45-9 Previous Diagram See: 8W-45-7 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2838 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-9 Next Diagram See: 8W-45-10 Previous Diagram See: 8W-45-8 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2839 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-10 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2840 Next Diagram See: 8W-45-11 Previous Diagram See: 8W-45-9 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-11 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2841 8w-45-11 Next Diagram See: 8W-45-12 Previous Diagram See: 8W-45-10 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-12 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2842 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-12 Next Diagram See: 8W-45-13 Previous Diagram See: 8W-45-11 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2843 Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-13 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-13 Next Diagram See: 8W-45-14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2844 Previous Diagram See: 8W-45-12 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-14 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2845 8w-45-14 Next Diagram See: 8W-45-15 Previous Diagram See: 8W-45-13 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2846 8W-45-15 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-15 Next Diagram See: 8W-45-16 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2847 Previous Diagram See: 8W-45-14 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-16 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2848 8w-45-16 Next Diagram See: 8W-45-17 Previous Diagram See: 8W-45-15 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-17 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2849 8w-45-17 Next Diagram See: 8W-45-18 Previous Diagram See: 8W-45-16 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-18 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-18 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2850 Next Diagram See: 8W-45-19 Previous Diagram See: 8W-45-17 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-19 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2851 8w-45-19 Next Diagram See: 8W-45-20 Previous Diagram See: 8W-45-18 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-20 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2852 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-19 Previous Diagram See: 8W-45-19 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2853 Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced as an assembly only. Attempting to remove or repair certain system subcomponents may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 2856 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description Body Control Module: Description and Operation System Description IDENTIFICATION OF SYSTEM The vehicle systems that are part of the body system are: - Adjustable Pedal System (APS) - Airbag System - Audio - Automatic Temperature Control - Cabin Heater - Chime - Communication - Door Ajar System - Electrically heated system - Exterior lighting - Instrument Cluster - Interior Lighting - Manual Temperature Control - Memory Seat - Overhead Console - Park Assist - Power Door Lock/RKE - Power Folding Mirrors - Power Sliding Doors - Power Liftgate - Power windows - Telecommunications (hands free phone) - Tire Pressure Monitor System (TPMS) - Vehicle Theft Security System (VTSS) - Windshield Wiper and Washer SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 2005 RS and RG consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate modules. All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages addressed to it through binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the Communication Section of this general information. The Body Control Module (BCM) is located in the passenger compartment, attached to the bulkhead underneath the left side of the instrument panel. The BCM utilizes integrated circuitry and information carried on the Programmable Communications Interface (PCI) data bus network along with many hard wired inputs to monitor many sensor and switch inputs throughout the vehicle. In response to those inputs, the internal circuitry and programming of the BCM allow it to control and integrate many electronic functions and features of the vehicle through both hard wired outputs and the transmission of electronic message outputs to other electronic modules in the vehicle over the PCI data bus. The Body Control Module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the BCM is interfaced to the vehicle's serial bus communications network, referred to as the Programmable Communications Interface (PCI) bus. This network consists of the; - Powertrain Control Module (PCM) - Transmission Control Module (TCM) - Mechanical Instrument Cluster (MIC) - Occupant Restraint Controller (ORC) - Compass/Mini-Trip Computer (CMTC) - Electronic Vehicle Information Center (EVIC) - Controller Antilock Brake (CAB) - HVAC Control Module - Sliding Door Control Modules (driver and passenger side doors) - Power Liftgate Module (PLG) - Audio system equipped with RAZ, RBU, RBK, and RBB radios. - Sentry Key Remote Entry Module (SKREEM). - Side Impact Airbag Control Module (SIACM) - Memory Seat Module (MSM) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2859 - Sentry Key Immobilizer Module (SKIM) The BCM is operational when battery power is supplied to the module. The BCM provides the following features: - Power Door Locks - Automatic Door Locks - Battery Protection - The BCM will automatically turn off all exterior lamps after 3 minutes, and all interior lamps after 15 minutes after the ignition is turned off, if they are not turned off by the driver. - Chime Control - Compass/Mini-Trip support. - Interior Lighting (Courtesy/Reading Lamps) - BCM Diagnostic Reporting - Electronic Liftgate Release (with Power Door Locks) - Exterior Lighting - Headlamp Time Delay (with/without Automatic Headlamps) - Illuminated Entry - Fade to Off Interior Lamps - This feature dims the interior lighting (courtesy lamps) gradually if the BCM does not receive any new inputs that would cause the interior lamps to remain on. - Pulse Width Modulated Instrument Panel Dimming - Door Lock Inhibit - This feature disables the door lock functions if the key is in the ignition and either front door is ajar. Pressing the Remote Keyless Entry (RKE) lock/unlock button under these conditions result in normal lock/unlock activation. Learned Features The BCM has the ability to LEARN additional features in the vehicle, provided the appropriate switch input and PCI data bus messages are received. Refer to the LEARNED FEATURES table. When replacing a BCM there are three modules available: - Base - Midline - RG - Export Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2860 The Midline controller is used on vehicles that have Power Door Locks. If a vehicle is equipped with the Vehicle Theft Security System, the Midline controller becomes a Premium when the theft feature is enabled. CAUTION: Do not swap Body Control Modules between vehicles or body controller's off the shelf. The BCM has internal diagnostic capability that assists in diagnosing the system error. When an OPEN or a SHORT circuit exists, the diagnostic tool can be used to read the BCM faults. The faults are very descriptive in identifying the appropriate feature that has faulted. The only two faults that the BCM logs that conclude the replacement of a BCM are faults; - # 01 - Internal BCM failure (replace BCM) - # 1F - J1850 Internal Hardware Failure (replace BCM) Otherwise the appropriate diagnostic procedures for each of the features should be taken when the BCM logs a fault. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2861 Body Control Module: Description and Operation Functional Operation Adjustable Pedals System The Adjustable Pedals are designed to enable the fore and aft repositioning of the brake and accelerator pedals. This results in improved ergonomics in relation to the steering wheel for taller and shorter drivers. Being able to adjust the pedal positions also allows the driver to set steering wheel tilt and seat positions to the most comfortable position available. The positions can be adjusted without compromising safety or comfort in actuating the pedals. Repositioning the pedals does not change the effort required for actuation. Changing of pedal position is accomplished by means of a motor. Operating the adjustable pedal switch activates the pedal drive motor. The pedal drive motor changes the position of the brake and accelerator pedals. The pedal can move rearward or forward. The pedals are moved to a position that is most comfortable for the driver. The accelerator and brake pedals are moved at the same rate to ensure synchronization. Neither the motor nor mechanisms are subject to mechanical stress of brake or accelerator application. The adjustable pedals feature is available on a non-memory/memory-equipped vehicle. The non-memory system consists of a mechanical switch that allows pedal travel adjustment. The IPM controls the Fused B+ circuit voltage to the adjustable pedals switch through the adjustable pedals relay. The circuit opens when the IPM detects an active cruise control state or when the vehicle is in reverse. The adjustable pedals control switch is located on the right side steering column shroud. The switch is hardwired directly to the adjustable pedals motor. When the operator actuates the switch to adjust the pedals, voltage is applied to the adjustable pedals motor allowing adjustment. The memory system, known as the Memory Seat Mirror Adjustable Pedal Module (MSMAPM), is located under the driver's seat and controls the adjustable pedals. The adjustable pedals control switch is located on the right side steering column shroud. The switch is hardwired directly to the MSMAPM. When the operator actuates the switch to adjust the pedals, the MSMAPM controls the adjustable pedals motor movement with input from the adjustable pedals sensor. This sensor allows pedal adjustment and memory functions to be recalled from the driver door mounted memory buttons or the RKE transmitters. The adjustable pedals will not operate when in an active cruise control state or when the vehicle is in reverse. Part 1 of 2 AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM AND OCCUPANT CLASSIFICATION SYSTEM The Airbag System contains the following components: Occupant Restraint Controller (ORC), Air-bag Warning Indicator, Clockspring, Driver and Passenger dual squib Airbags, Driver and Passenger Seat belt Tensioner (SBT), Driver and Passenger Hall-effect Seat Belt Buckle Switches (SBS), Left and Right Side Curtain Airbags, and Front and Side Impact Sensors. The ORC also monitors the Occupant Classification System (OCS) for the presence of a passenger in the front outer seat. The Occupant Classification System contains the following components: Occupant Classification Module (OCM), Bladder and Sensor, Belt Tension Sensor, and Passenger Airbag off Indicator. The Occupant Restraint Controller (ORC) supports staged airbag deployment and remote impact sensing. Staged deployment is the ability to trigger airbag system squib inflators individually as needed to provide the appropriate restraint for the severity of the impact. The ORC has four major functions: PCI Bus communications, onboard diagnostics, impact sensing, and component deployment. The ORC also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the front airbag components for two seconds following a battery disconnect or failure during an impact. The ORC is secured to the floor panel transmission tunnel below the instrument panel inside the vehicle. The ORC cannot be repaired or adjusted. The ORC sends and/or receives PCI Bus messages with the Instrument Cluster (MIC), Body Control Module (BCM), and Powertrain Control Module (PCM). Diagnostic trouble codes will be set if the communication with these modules is lost or contains invalid information. The microprocessor in the ORC monitors the front impact sensor signals and the airbag system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sends a message to the instrument cluster via PCI bus to turn on the Airbag Warning Indicator. The ORC can set both active and stored diagnostic trouble codes to aid in diagnosing system problems. See DIAGNOSTIC TROUBLE CODES. The ORC uses an internal accelerometer, two front sensors and six side impact sensors, to sense the rate of vehicle deceleration and provide verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ORC microprocessor determines when the deceleration rate is severe enough to require airbag system protection. The ORC also uses the driver and passenger seat belt switch status (buckled or unbuckled) to determine the level of driver airbag deployment, low medium or high. When the programmed conditions are met, the ORC sends an electrical signal to deploy the appropriate airbag system components. WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS CAN RESULT IS ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. - NEVER STRIKE OR KICK THE OCCUPANT RESTRAINT CONTROLLER, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. The Airbag Warning Indicator is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2862 turned to the run or start position, the ORC performs a lamp check by turning the Airbag Warning Indicator on for 6-8 seconds. After the lamp check, if the indicator turns off, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes off, there is usually an intermittent problem in the system. DRIVER AIRBAG The airbag protective trim cover is the most visible part of the driver side airbag system. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. When supplied with the proper electrical signal, the inflator or inflators discharge the gas directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE DRIVER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 17236.89 kPa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. CAUTION: Deployed Front Air Bags may or may not have live pyrotechnic material within the air bag inflator. Do not dispose of Driver and Passenger Airbags unless you are sure of complete deployment. Please refer to the Hazardous Substance Control System for Proper Disposal. Dispose of deployed air bags in a manner consistent with state, provincial, local, and federal regulations. Use the following table to identify the status of the Airbag Squib. AIRBAG SQUIB STATUS 1. Using a DRBIII(R) read Airbag DTC's If the following active codes are present: If neither of the following codes is an active code: ACTIVE DTC SQUIB STATUS Driver squib 1 open Driver Squib 2 open Status of Airbag is Unknown. CLOCKSPRING The clockspring is mounted on the steering column under the steering wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wiring and the driver airbag, the horn, and the vehicle speed control switches if equipped. The clockspring Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2863 must be properly centered when it is reinstalled on the steering column following any service procedure, or it could be damaged. The clockspring cannot be repaired and it must be replaced. PASSENGER AIRBAG The front passenger airbag is equipped with dual stage squib inflators. When supplied with the proper electrical signal the inflator or inflators discharge the gas directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS INERT GAS PRESSURIZED TO 17236.89 kPa (2500 PSI). DO NOT ATTEMPT TO IS MANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR.DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. AIRBAG SQUIB STATUS 1. Using a DRBIII(R) read Airbag DTC's If the following active codes are present: If neither of the following codes is an active code: ACTIVE DTC SQUIB STATUS Passenger squib 1 open Passenger squib 2 open Status of Airbag is Unknown. CAUTION: Deployed Front Air Bags may or may not have live pyrotechnic material within the air bag inflator. Do not dispose of Driver and Passenger Airbags unless you are sure of complete deployment. Please refer to the Hazardous Substance Control System for Proper Disposal. Dispose of deployed air bags in a manner consistent with state, provincial, local, and federal regulations. Use the following table to identify the status of the Airbag Squib. SEAT BELT TENSIONER (SBT) The driver and passenger seat belt (buckle) tensioners are mounted to the inboard side of the front seats. The seat belt buckle and seat belt switch are connected directly to the seat belt tensioner cable. At the onset of an impact event the ORC uses the seat belt tensioner to rapidly retract the seat belt buckles. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. The seat belt tensioner cannot be repaired, if damaged or defective it must be replaced. The ORC continuously monitors the resistance of the seat belt tensioner circuits for open and shorted conditions. SEAT BELT SWITCHES (SBS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2864 The hall-effect driver and passenger seat belt switches provide the seat belt status, buckled or unbuckled, via hardwired inputs to the ORC. If the seat belt switch is damaged or defective the seat belt tensioner must be replaced. The ORC continuously monitors the seat belt switch circuits for open and shorted conditions. DRIVER KNEE BLOCKER AIRBAG The most visible part of the Driver Knee Blocker Airbag is the knee blocker trim cover. The knee blocker trim cover and airbag are mounted directly to the instrument panel structure below the steering column. When supplied with the proper electrical signal, the inflator discharges the gas directly into the airbag. The airbag cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: - DO NOT ATTEMPT TO MODIFY ANY PART OF YOUR ADVANCED AIRBAG SYSTEM. THE AIRBAG MAY INFLATE ACCIDENTALLY OR MAY NOT FUNCTION PROPERLY IF MODIFICATIONS ARE MADE. TAKE YOUR VEHICLE TO AN AUTHORIZED DEALER FOR ANY ADVANCED AIRBAG SYSTEM SERVICE. IF YOU'RE SEAT INCLUDING YOUR TRIM COVER AND CUSHION NEEDS TO BE SERVICED IN ANY WAY (INCLUDING REMOVAL OR LOOSENING/TIGHTENING OF EAT ATTACHMENT BOLTS), TAKE THE VEHICLE TO YOUR AUTHORIZED DEALER. ONLY MANUFACTURER APPROVED SEAT ACCESSORIES MAY BE USED. CONTACT YOUR AUTHORIZED DEALER IF IT IS NECESSARY TO MODIFY AN ADVANCED AIRBAG SYSTEM FOR PERSONS WITH DISABILITIES. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. FRONT AND SIDE IMPACT SENSOR The front and side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, and combined with the ORC Accelerometer Sensor provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller. The ORC microprocessor continuously monitors all of the front and side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a system fault, it sets a Diagnostic Trouble Code and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor signal and ground circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor signal circuit. If the sensor is dropped it must be replaced. CAUTION: Do not remove or install the impact sensors while the sensor is connected to the vehicle wiring. OCCUPANT CLASSIFICATION SYSTEM A non-calibrated Occupant Classification Module (OCM) is the only component of the Occupant Classification System (OCS) that is available for separate service replacement, as outlined in the procedures that follow. The OCS components of the passenger side front seat cushion including the cushion frame, springs, pad, seat weight bladder and pressure sensor, seat cushion foam and the OCM are a factory-calibrated and assembled unit. Once this unit is connected to a vehicle electrically, the calibration settings are uploaded from the OCM and stored in the memory of the Airbag Control Module (ORC). If only the OCM is subsequently replaced, the new, non-calibrated OCM learns the proper calibration settings from the ORC after it is connected to the vehicle electrically. If any of the remaining OCS components of the passenger side, front seat cushion require replacement, they are serviced only as a factory calibrated, assembled, and tamper-evident service replacement package. This package includes the assembled frame, springs, pad, seat weight bladder and pressure sensor, foam, wiring and a calibrated OCM. When installing this package, always replace all of the existing components with the new components as a unit. Do not attempt to separate or disconnect any of the new OCS components contained in the service replacement package from each other, and do not attempt to reuse any of the replaced components in this or any other vehicle. Once any of the original factory-installed components except the OCM have been replaced with the service replacement package components, the OCM can only be serviced by replacing the entire passenger side front seat cushion unit with another complete service replacement package. CAUTION: On vehicles equipped with the Occupant Classification System (OCS), never replace both the Airbag Control Module (ORC) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one. Then perform the supplemental restraint verification test before replacing the other. Both the ORC and the OCM store OCS calibration data, which they transfer to one another when one of them is replaced. If both are replaced at the same time, an irreversible fault will be set in both modules. The OCM is subsystem of the Airbag Control Module (ORC). Therefore the OCM bus message updates the ORC with the front passenger seat information via PCI Bus message. The ORC then controls the Passenger Off indicator and the Airbag Warning Indicator to provide system onboard diagnostic feedback. All OCS wiring repairs are prohibited; when wiring problems are diagnosed a Bladder Repair Kit is the only approved repair. Part 2 of 2 PASSENGER AIRBAG OFF INDICATOR Vehicles equipped with the Occupant Classification System (OCS) include a passenger airbag off indicator located in the Switch Bank in the center of the instrument panel. Vehicles without OCS have a blank lens installed in the instrument panel. At ignition on, for a system test, the ORC low side driver grounds a yellow Light Emitting Diode (LED) circuit causing the PASS AIRBAG OFF Indicator text and icon to be illuminated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2865 SEAT WEIGHT SENSOR Vehicles equipped with the Occupant Classification System (OCS) have a seat weight bladder and pressure sensor unit that is integral to the passenger front seat cushion. The pressure sensor receives a nominal five volts and a ground through dedicated hardwired circuits from the OCM. The OCM then monitors the pressure sensor output voltage. SEAT BELT TENSION SENSOR - BTS The Belt Tension Sensor (BTS) is designed to measure belt tension as an input to a passenger Occupant Classification System (OCS). It is used to detect high cinch loads associated with child seats and compensate for the seat cushion load to correctly classify occupant size. When a load is applied to the seat belt, the belt tension sensor measures the load. As the load changes, the circuitry of the belt tension sensor changes the output voltage of the sensor. The belt tension sensor receives a nominal five volts and a ground through dedicated hardwired circuits from the OCM. The OCM then monitors the belt tension sensor output voltage on a dedicated hardwired data communication circuit. If the vehicle has experienced any impact(s) resulting in deployment of a pyrotechnic device of any kind (airbag, seatbelt tensioner, side curtain, etc.) within the vehicle, the entire passenger seat belt retractor assembly, including the BTS, shall be replaced. Additionally, if the seat belt webbing has become cut, frayed, or worn; or if the stitching has become damaged in any way, the entire passenger seat belt retractor assembly, including the BTS, shall be replaced. The belt tension sensor cannot be repaired and, if faulty or damaged, the entire passenger side front seat belt and retractor unit must be replaced. The OCM Verification Test will also provide a BTS Verification procedure to verify the BTS function. This verification procedure requires the Miller Special Tool #8828. BLADDER REPAIR KIT There are only three replaceable components in the OCS, Occupant Classification Module, Bladder Repair Kit and the Passenger Airbag OFF Indicator. The Bladder repair kit contains the OCS bladder, wire harnesses, pressure sensor (Seat Weight Sensor), module, seat cushion and other related structural and sound deadening components. The module and sensor connector must have a Tamper Evident material installed on the service kit module and sensor connectors. This material provides visible evidence that the assembly has been separated after the calibration process was completed. Do not install a Bladder Repair Kit if it appears that any of the components have been disconnected. The OCM can be replaced if the Airbag Control Module has uploaded the seat calibration into memory in a previous ignition cycle and the new OCM has a blank VIN and no calibration data stored in memory. NOTE: - An OCM can only be replaced in a passenger front seat if the seat is equipped with the original OCS module, bladder, sensor and wiring. - Servicing the OCS may create additional active and stored trouble codes that must be resolved before the vehicle can be returned to the owner. The OCS Verification Test will also set active DTC's if the procedure is not completed successfully. The Miller Special Tool, MRL-9077 and the DRBIII are needed to successfully complete the system Verification Test. The DRBIII(R) may report the following NEW DRBIII(R) FEATURE ORC Menu The DRBIII(R) ORC System Test screen will display the following: 2VIN verification - Original VIN and Current VIN 2PCM Monitor - PCM Active On The Bus or PCM Not Active On The Bus The DRBIII(R) ORC Input/Outputs screen will display the following: - OCM Status: - Seat Class 0 (Empty) - Seat Cass 1 (Rear Facing Infant car Seat or RFIS) - Seat Class 2 (6 year old or Child) - Seat Class 3 (greater than or equal to 5th Percentile Female) - Seat Class 4 (less than 5th Percentile Female) - Seat Class 5 (Undetermined) The DRBIII(R) ORC Miscellaneous screen will display the following: - Configure Airbag On-Off Switch 1. No Airbag On-Off Switch 2. Pass OCM Only OCS Menu The DRBIII(R) OCM Input/Output screen will display the following: - OCS Status - 90, 919, 929, 939, 949, 959 The DRBIII(R) OCM Sensors screen will display the following: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2866 - Bladder Output - XXX A/D counts - Pas BTS Output - XXX A/D counts The DRBIII(R) OCM OCS Info Monitor screen will display the following: - Pass BTS -- Enabled or Disabled System Verification The DRBIII(R) OCM System Test screen will display the following: - PCM Monitor - PCM Active On The Bus or PCM Not Active On The Bus - Clear VIN Mismatch - Clear VIN Mismatch Complete - VIN Verification - Original VIN and Current VIN Clear VIN Mismatch - OCS Verification - OCS Verification Test process errors: Test In Progress Mode 33 Not Supported Subfunction not supported Test Busy - Repeat Test Conditions for Test Not Correct Routine Already Running Routine was Never Started Press any key to continue, then restart the verification test. Test failed conditions: Test Failed - Active DTC's Present Test Failed - Seat is Empty Test Failed - Seat Occupied Test Failed - Weight Above Threshold Test Failed - Weight Below Threshold Test Failed - Temperature Out of Range Test Failed - Seat Pressure Too High Test Failed - Seat Pressure Too Low Test Failed - Seat Pressure Not Stable Test Failed - Temperature Out of Range Test Failed - Seat Pressure Too Low Test Failed - Power Up Time Too Short Test Failed - Power Up Time Too Long Test Failed - K Empty Count is 0 Test Failed - No EOL Calibration Test Failed - K Allow is FF Allow the vehicle seat and interior temperature to stabilize, check voltage supplies and repair any other active DTC's before restarting the System Verification test. The OCS has been Verified or The OCS has NOT been Verified WARNING: - TO AVOID PERSONAL INJURY OR DEATH, TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING. - TO AVOID PERSONAL INJURY OR DEATH, TURN THE IGNITION ON, THEN RECONNECT THE BATTERY. - TO AVOID PERSONAL INJURY OR DEATH ON VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS), ONLY THE OCCUPANT CLASSIFICATION MODULE (OCM) AND THE PASSENGER SEAT BLADDER AND CUSHION SERVICE KIT ARE THE ONLY PARTS SERVICED. - IF THE OCCUPANT CLASSIFICATION MODULE IS DROPPED AT ANY TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. TO AVOID PERSONAL INJURY OR DEATH ON VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS), ONLY THE OCCUPANT CLASSIFICATION MODULE (OCM) AND THE SEAT CUSHION TRIM MAY BE SERVICED SEPARATELY. ALL OTHER COMPONENTS OF THE PASSENGER SIDE FRONT SEAT CUSHION ASSEMBLY MUST BE SERVICED ONLY AS A COMPLETE FACTORY-CALIBRATED, ASSEMBLED AND TAMPER-EVIDENT SERVICE REPLACEMENT PACKAGE. THIS PACKAGE INCLUDES THE FRAME, SPRINGS, PAD, BLADDER AND PRESSURE SENSOR, FOAM, WIRING AND A CALIBRATED OCM. WHEN INSTALLING THIS PACKAGE ALWAYS REPLACE ALL OF THE EXISTING COMPONENTS WITH THE NEW COMPONENTS AS A UNIT. DO NOT ATTEMPT TO SEPARATE OR DISCONNECT Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2867 ANY OF THE NEW OCS COMPONENTS IN THE SERVICE REPLACEMENT PACKAGE FROM EACH OTHER, AND DO NOT ATTEMPT TO REUSE ANY OF THE REPLACED COMPONENTS IN THIS OR ANY OTHER VEHICLE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN FAILURE OF THE PASSENGER AIRBAG TO DEPLOY WHEN REQUIRED, OR IN PASSENGER AIRBAG DEPLOYMENT WHEN NOT REQUIRED. SPECIAL TOOLS Some airbag diagnostic tests will require the use of special tools, airbag load tools, 8443 for testing squib circuits and the Occupant Classification Seat Weight Tool 9077. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of a Driver or Passenger Airbag, curtain airbag, clockspring, or seat belt tensioner (use a jumper if needed). Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective component has been removed from the system and should be replaced. If the DTC is still active, continue this process until all components in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed the squib wiring can be tested for open and shorted conditions. DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes with the DRBIII(R). This will direct you to the specific test(s) that must be performed. In certain test procedures diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The code becomes active as soon as the malfunction is detected or key-on, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the Occupant Restraint Controller checks that circuit or component. It is impossible to erase an active code. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. STORED CODES Airbag codes are automatically stored in the ORC's memory as soon as the malfunction is detected. A stored code indicates there was an active code present at some time. When a trouble code occurs, the Airbag Warning Indicator illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). Once the code is no longer active, the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected will be displayed. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. The ignition cycle counter will be reset and diagnostic trouble code will continue to be a stored code, If the malfunction reoccurs before the count reaches 100. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. Maintain a safe distance from all airbags while performing the following inspection. If no obvious problems are found, erase stored codes, and with the ignition on wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Audio System Some of the radios are on the PCI Bus system. The PCI Bus inputs into the radio are used for VF dimming, remote steering wheel controls and cabin EQ preference. PCI Bus outputs from the radio are used for the Name Brand Speaker (NBS) relay activation, as well as cabin EQ preference. The radios have the capability of containing multiple vehicle unique equalization curves (cabin EQ preferences) within the radio. These curves will reside in the radio's flash memory. The radio is capable of storing up to 20 unique equalization curves. The latent curves can be selected via the Front Control Module transmitting a PCI Bus message to the radio in response to a radio request for equalization message. Upon receipt of a valid equalization select message response, the radio will switch to output the corresponding equalization curve. All the radios are capable of displaying faults and allowing certain actuation tests through the use of the DRBIII(R). When attempting to perform PCI Bus diagnostics, the first step is to identify the radio in use in the vehicle. When trouble shooting output shorts or 'output' error messages, the following applies: On radios without an external amplifier, the term output refers to the path between the radio and the speaker. This type of circuit can be monitored all the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2868 way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio, or wiring could be at fault. On radios with an external amplifier, the term 'output' refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. NAVIGATION RADIO The optional navigation radio system receives GPS signals from up to eight satellites to display the position and direction of the vehicle. Map information is supplied through a DVD-ROM. An electronic gyrosensor and the vehicle's speed sensor enable the system to display the present vehicle position even in locations where GPS signals may be blocked. When a destination is selected, the navigation system uses information from the map to quickly calculate a route. As the vehicle is driven along the chosen route, the operator is guided with pictorial displays and voice prompts. For complete operating instructions, refer to the manual included with the vehicle. REMOTE RADIO CONTROLS These radios can be controlled via remote radio switches (optional). These switches are located on the back side of the steering wheel. They control mode, preset, seek up, seek down, volume up and volume down functions. These functions are inputs to the Body Control Module and can be read with the DRBIII(R) under 'body computer'. The switches are a multiplexed signal to the BCM. The radio control MUX circuit is a 5 volt line that is pulled to ground through different value resistors built into the switches. This causes a voltage drop to be seen by the BCM and it sends a specific message to the radio on the PCI Bus circuit. The radio then responses to the message. This circuit is fairly simple to troubleshoot. The circuit must be complete from the switches in the steering wheel to the BCM. The ground must be complete so that the switches can cause the voltage drop for the BCM to see. The circuit passes through the clockspring so continuity through this devise must be verified. CD CHANGER The new in-dash CD Changer is designed to fit into the existing cubby bin in the center stack. This new cartridge-less CD Changer is controlled by your radio, and allows you to individually load up to four discs at a time. However, due to its compact design, the CD Changer can only carry out one operation at a time. For example, you can not load a new disc while playing another at the same time. Each operation happens sequentially. The radio unit installed with your system provides control over all features of the CD Changer with the exception of the CD load and eject functions, which are controlled by buttons located on the front of the CD Changer. The radio also supplies the power, ground, PCI Bus, left and right speaker output through a single DIN cable. All features you would expect, such as Disc Up/Down, Track Up/ Down, Random and Scan are controlled by the radio, which also displays all relevant CD Changer information on the radio display. The CD Changer contains a Load/Eject button and an indicator light for each of the four disc positions. The individual light indicates whether a CD is currently loaded in that particular chamber of the CD Changer. Pressing the individual Load/Eject button for a particular chamber will eject a disc currently present in that chamber. If the chamber is currently empty, actuating the Load/Eject button will position that chamber to receive and load a new disc in that chamber. DVD/CD CHANGER The DVD/CD Changer (if equipped) is located in the instrument panel below the radio. The DVD/CD Changer can hold one DVD at a time. Three RCA jacks on the front of the unit will allow the use of MP3 players, video systems or camcorders. Body Control Module The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (PCI). This network consists of the powertrain control module (PCM), the engine control module (ECM) diesel, the mechanical instrument cluster (MIC), the front control module (FCM), the occupant restraint controller (ORC), the occupant classification module (OCM), the overhead console, the ABS module, the hands free module (HFM), the park assist module, the HVAC control module (ATC & MTC), the power sliding door (Left & Right) modules (PSD), the power liftgate module (PLG), the Audio system (which includes the Radio, DVD, CD Changer and Amplifier), the memory seat/mirror/ adjustable pedals module (MSMAPM), the RKE/ Thatcham alarm module (export), the transmission control module (Diesel only) and the sentry key remote entry module (SKREEM). The BCM is operational when battery power is supplied to the module. The body control module provides the following features: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2869 - Power Door Locks - Automatic Door Lock - Door Lock Inhibit - Central Locking (with VTSS Only) - Battery Protection - The BCM will automatically turn off all exterior lamps after 3 minutes and all interior lamps after 15 minutes after the ignition is turned off, if they are not turned off by the driver. - Chime Driver - Compass/Minitrip Support - Interior Lighting (Courtesy/Reading Lamps) - BCM Diagnostic Reporting - Electronic Liftgate Release (with Power Door Locks) - Exterior Lighting - Headlamp Time Delay (with/without Auto headlamps) - Automatic Headlamps (with electrochromatic mirror) - Illuminated Entry - Fade to Off This feature dims the interior lighting (courtesy lamps) gradually if the BCM does not receive any new inputs that would cause the interior lamps to remain on. - PWM Instrument Panel Dimming - Door Lock Inhibit This feature disables the door lock functions if the key is in the ignition and either front door is ajar. Pressing the RKE lock/unlock button under these conditions, result in normal lock/unlock activation. - Power Sliding Door Switch Inputs The BCM has 4 switch inputs for the power sliding door feature: Located in the overhead console are the Left and Right side sliding door switches to activate either or both sliding doors under the proper conditions. Also there are B-Pillar switches located on the Left and Right B-pillar posts. - Power Liftgate Switch Input The BCM has 1 Liftgate switch input located in the overhead console - Power Lockout Switch Input The BCM has 1 Lockout switch that when enabled will disable the B-Pillar sliding door switches from activating either sliding door when depressed. When replacing a body control module there are 2 modules available, a Base and a Midline. The Midline controller is used on vehicles that have Power Door Locks. If a vehicle is equipped with the Vehicle Theft Security System, the midline controller becomes a premium when the theft feature is enabled. NOTE: Do not swap the body control module between vehicles or body control modules off the shelf. Engineering does not recommend that service, dealers or the plant swap Body Control Modules (BCM) between vehicles or off the shelf. The BCM has internal diagnostic capability that assists in diagnosing the system. When an 'open' or a 'Short' circuit exists, the diagnostic tool can be used to read the BCM codes. The codes are very descriptive in identifying the appropriate feature that has faulted. The BCM also learns what features are on the vehicle and if modules are swapped the BCM could set false DTC's based on what it learned. Chime Warning System The BCM monitors the door/liftgate ajar switches, multifunction switches, headlight switch, ignition switch, PCI bus, and the diagnostic tool to perform various chime operations. The BCM uses a low-side driver to control the chime located in the cluster. The chime system provides the Driver with warning chimes for: - Seat belt - Exterior lights on - Key-in Ignition - Key-in Accessory - Engine temperature critical - Low washer fluid - Turn signals on - Dome light on - Low oil pressure - Any warning lamp announcement - High-speed warning Gulf Coast Countries (GCC) only The output sound intensity of the chime is approximately 72 decibels. CHIME PRIORITY Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2870 The following list indicates the priority of the chime when more than one chime is active at the same time: - Seat belt warning - High-speed warning Gulf Coast Countries (GCC) only - Turn signal on - Chime request - Warning lamp announcement The cluster is responsible to set priority on all warning lamp announcement chimes. CHIME ON CONDITIONS The following is a list of the chime warnings and when they will sound. Driver's Seatbelt Unbuckled: Sounds for approximately 6 ± 2 seconds when the ignition is turned on driver's seat belt is not buckled, as a reminder to the driver to buckle the seat belt. Exterior Lights On:Ignition is in the lock position, the driver door is ajar, and the headlight switch is left in any position, other than auto or off.The chime will sound as a warning to the driver until one of the above conditions is removed or until the battery protection time of 3 minutes has expired. Key-In Ignition: Ignition is in the lock position, driver door is ajar and the key is in the ignition. The chime will sound until one of the above conditions is removed or until the battery protection time of 15 minutes has expired. Turn Signal On: When the BCM detects a turn signal input continuously for 1.0 mile/0.6 km and the vehicle speed is greater than 15 mph/24 kph, the chime will sound until the specific turn signal is cancelled. Dome Lights On: Ignition is in the lock position, driver door ajar, and the dome light switch is left in the on position. The chime will sound until one of the above conditions is removed or until the battery protection time of 15 minutes has expired. Low Oil Pressure: The chime will sound when the engine is operating and the oil pressure drops below 4 psi/27.5 kPa. Engine Temperature Critical: The chime will sound when the engine is operating and the coolant temperature exceeds 252° F/122° C or 234° C/112° C(diesel). The chime is continuous at 257° F/ 125° C and will chime for 4 minutes and stop if the temperature drops below 255° F/123° C. Low Washer The chime will sound when the Fluid washer fluid drops below a specific level. Warning Lamp Announcement: A chime will sound to alert the driver to scan the instrument panel and overhead console to see which warning lamp is illuminated. The door/liftgate ajar warning lamp will appear without a chime if the vehicle is running and a door or the liftgate is opened. A chime will sound if the door or liftgate is still open and the vehicle speed is greater than 4 mph/6 kph. High-speed warning Gulf Coast Countries (GCC) only The chime will sound, acting as a warning to the driver that the vehicle speed has exceed 75 mph ± 2/120 kph ± 3. WARNING LAMP ANNOUNCEMENT Low Fuel Lamp: The cluster will request a single chime after the indicator is illuminated. Volt Lamp: The cluster will request a single chime after the indicator is illuminated. Oil Pressure Lamp: The cluster will request a single chime after illuminating the indicator above 450 rpm vehicle operation. Liftgate Ajar Lamp: The BCM determines when to chime for liftgate ajar. Fasten Seat Belt Lamp: The MIC will request a single chime from the BCM when the ignition is turned to the unlock/ run/start positions if the driver seat belt is not buckled and 2 seconds after seatbelt warning chime ends. Check Engine Lamp: The cluster will request a single chime after the indicator is illuminated. Low Washer Fluid Lamp: The cluster will request a single chime after the indicator is illuminated. Engine Temperature Lamp: The cluster will request a single chime when the indicator is first illuminated at 252° F/122° C. OTHER CHIME ON CONDITIONS Programming of an Additional Key Fob: A single cluster chime will sound, which signals that the program mode has been initiated. Programming for Rolling Door Locks: When the programming has been completed, a single tone from the chime system, will occur. Communication Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2871 The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25 and is white with a violet tracer. Additional tracer colors may be added to the violet in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on the RS/RG: - Body Control Module - Front Control Module - Occupant Restraint Controller - Occupant Classification Module - Controller Antilock Brake (MK20E) - Antilock Brake Module (MK25E) - Powertrain Control Module (Gas) - Transmission Control Module (Diesel Auto Only) - Engine Control Module (Diesel) - Radio - Amplifier - CD Changer - DVD/CD Changer - Hands Free Module - Automatic Temperature Control Module - A/C Heater Control Module (MTC) - Sentry Key Remote Entry Module (SKREEM) - Memory Seat/Mirror/Adjustable Pedals Module (MSMAPM) - Overhead Console - Mechanical Instrument Cluster - Left Sliding Door Control Module - Right Sliding Door Control Module - Thatcham Alarm Module (Export) - Power Liftgate Module - Park Assist Module Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRBIII(R) lab scope. The 12 v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open PCI circuit at the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: - All gauges on the MIC stay at zero - All telltales on MIC illuminate - MIC backlighting at full intensity - Dashed lines in the overhead console ambient temperature display - No response received from any module on the PCI bus (except the PCM/ECM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRBIII(R). Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected,suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRBIII(R) If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRBIII(R) may display BUS ± SIGNAL OPEN or NO RESPONSE to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRBIII(R) and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. NOTE: For 2005 model year, some vehicles will integrate the Transmission Control Module and Powertrain Control Module into a single control module. This new module is the Next Generation Controller for DaimlerChrysler and will be referred to as the Powertrain Control Module (PCM). The Transmission Control Module is part of the Powertrain Control Module. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2872 Diagnostic procedures and DTC numbers are some of the changes you will see which reflect the new combined module technology. The PCM will have four color coded connectors C1 through C4, (C1-BLK, C2-ORANGE, C3-WHITE, C4-GREEN), each PCM connector will have 38 pins each. Two new tools are used for probing and repairing the New PCM connectors. A New tool to release the pins from the PCM connectors Miller #3638 is introduced, you must use the Miller tool #3638 to release the connector pins or harness and connector damage will occur. Also a New tool for probing connectors Miller #8815 is introduced, you must use the Miller tool #8815 to probe the PCM pins or harness and connector damage will occur. There is also a new Verification test and module replacement procedure for the PCM. Door Ajar System The door ajar and liftgate ajar states are used as inputs for the Body Control Module (BCM). The BCM uses these inputs to determine exactly what position the doors and liftgate are in. The DRBIII(R) will display the state of the door ajar and the liftgate ajar switches in Inputs/Outputs. It's important to note, that when any door, or the liftgate is closed, the switch state on the DRBIII(R) will show OPEN. When any door, or the liftgate is open the switch state on the DRBIII(R) will show CLOSED. During diagnosis, if a door or the liftgate is closed and the DRBIII(R) displays the switch state as CLOSED, it indicates a shorted ajar circuit. If the door or the liftgate is open and the DRBIII(R) displays the switch state as OPEN, it indicates an open ajar circuit. Exterior Lighting System HEADLAMP POWER The Headlamp Switch is a direct input to the BCM. The BCM sends a BUS message to the FCM informing it of a headlamp switch status change. The FCM then turns on power to the headlamps through four fuseless circuits. These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied to each filament in a separate circuit. For vehicles equipped with daytime running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination. HEADLAMP SWITCH The Headlamp Switch uses a multiplexed (MUX) circuit to the Body Control Module (BCM). The Headlamp Switch controls the Fog lamp relay, Park lamps and the Low and High headlamps. The BCM then sends a signal through the PCI Bus line to the FCM as to what state the switch has selected. The FCM energizes the high side output drivers to turn ON the desired lamps. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2873 PARK LAMP RELAY The Park Lamp Switch is a direct input to the BCM. The BCM sends a BUS message to the FCM informing it to turn on the park lamp relay. The park lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. FOG LAMP RELAY The Fog Lamp switch is a direct input to the BCM. The BCM sends a BUS message to the FCM informing it to turn on the fog lamp relay. The fog lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Fog lamp functionality is not equipped on all vehicles. The FCM learns that the vehicle is equipped with fog lamps by reading the BCM BUS message. FOG LAMPS The BCM controls the operation of the fog lamp relay that turns the fog lamps ON and OFF. The Fog lamps can only be ON when the park and low beams are ON. If the high beams are switched ON then the Fog lamps will be automatically turned OFF. EXTERIOR LIGHTING BATTERY SAVER The BCM monitors the status of, and controls, the Park Lamps, Headlamps and Fog Lamp relays. If any exterior lamps are left ON after the ignition is turned OFF, the BCM will turn them OFF after 3 minutes. AUTO HEADLAMPS This feature is available on vehicles equipped with both the Electrocromatic Mirror (ECM) and the Compass/Mini-Trip Computer (CMTC). When the BCM detects a day/night signal from the CMTC, an ECM is present and Auto Headlamp mode is selected. Front Control Module The Front Control Module (FCM) is an electrical control and interface center located in the engine compartment. When it is mated to the Power Distribution Center (PDC), it is referred to as the Integrated Power Module (IPM). The IPM, with its fuses and relays provides power and signal distribution throughout most of the vehicle. The FCM receives both hard wire and digital electronic inputs from the vehicle electrical system through the PDC. Based on these inputs and the ignition switch position, it provides direct power feeds and relay control to some of the vehicles most critical electrical systems. The Front Control Module provides the following features: Controlled power feeds: - Front airbag system - Headlamp power - EATX module power (4 speed only) - Front washer motor - Rear washer motor - Cabin Heater - Brake shift interlock system Relay controls: - Fog lamp relay (when equipped) - Park lamp relay - Front wiper on relay - Front wiper high/low relay - Accessory relay - Horn relay - Front & rear blower relay - Name brand speakers (NBS) relay - Adjustable pedals relay (non-memory) - Electronic back light (EBL) run only relay Electrical inputs: - Headlamp battery supplies 1 & 2 - Module battery supply - Power ground - Ignition switch RUN or START position status - Ignition switch START only status - PCI Bus - Stop lamp switch - Horn switch - Back-up switch - Wiper park switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2874 - Washer fluid level switch - Brake fluid level switch - Ambient temperature sensor - Right park lamp outage - Left park lamp outage - Battery IOD - Battery (+) connection detection - Flash reprogramming voltage CONTROLLED POWER FEEDS Front airbag system The FCM provides power to the Occupant Restraint Control (ORC) system through two fuseless circuits (ORC RUN/START, and ORC RUN only). These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied while the ignition switch is in the RUN and START positions on pin 48 of the FCM connector, and in the RUN only position on pin 29. Headlamp power The headlamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a headlamp switch status change. The FCM then turns on power to the headlamps through four fuseless circuits. These circuits are electronically controlled and continuously monitored for malfunctions.Power is supplied to each filament in a separate circuit. For vehicles equipped with Daytime Running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination. EATX power The electronic automatic 4 speed transmission module is powered when the ignition switch is in the UNLOCK, RUN or START positions. This circuit is electronically controlled and continuously monitored for malfunctions. Power is supplied through pin 27 of the FCM connector. Front washer motor The front washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The front washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition, the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Rear washer motor The rear washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The rear washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition,the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Cabin Heater When the ignition is in Run, the FCM monitors the PCI bus for the Cabin Heater Activation request. The Automatic or Manual Temperature Control initiates this request only when all conditions for the Cabin Heater activation are favorable. The request carries the status bit that the FCM requires to activate its Cabin Heater Assist Control output. This output is a low side driver (coming from FCM pin 15) which supplies a ground signal to the Cabin Heater (pin 5). When the Cabin Heater receives this ground signal input, it interprets this as an activation signal. The FCM low side driver is also capable of diagnostic sensing. The driver will sense an open circuit when the driver is off, and will sense a short to voltage when the driver is on. The FCM will set DTC's for both of these types of faults. For additional information, refer to Cabin Heater under General Information and Diagnostic Procedures in the manual. Brake shift interlock system The brake shift interlock solenoid receives power from both high side and low side controls inside the FCM. The high side control is on the same circuit as the EATX module power, and the low side control comes through pin 47 of the FCM connector. The solenoid is controlled by the low side driver when the brake pedal is pressed. Both circuits are continuously monitored for malfunctions. RELAY CONTROLS Fog lamp relay The fog lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the fog lamp relay. The fog lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Fog lamp functionality is not equipped on all vehicles. The FCM learns that the vehicle is equipped with fog lamps by reading the BCM PCI Bus message. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2875 Park lamp relay The park lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the park lamp relay. The park lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper on relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper on relay. The front wiper on relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper high/low relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper high/ low relay. The relay switches power between the low speed and high speed windings of the wiper motor. The front wiper high/low relay is powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Accessory relay The accessory relay works in conjunction with the FCM's power accessory delay feature to control the operation of the radio, power windows, washer motors,wiper motors and power outlet. The accessory relay is turned on through low side control on pin 35 of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Depending on the ignition switch position, the accessory relay will remain on or will time-out and turn off. The accessory relay remains on in the RUN and ACCY positions of the ignition switch. In the UNLK and OFF positions, the relay will remain energized for 45 seconds then turn off. During this time-out period, if the driver or passenger doors are opened, the relay will turn off immediately. While the ignition switch is in the START position, the relay will also drop-out, then resume operation. Accessory relay operation is most noticeable by observing the operation of the radio or blower functions. Horn relay The horn relay operates through a direct wire input to the FCM from the horn switch (FCM pin 17) , or a PCI Bus message from the BCM. The relay responds to the horn switch, remote door lock and VTA alarm functions. The horn relay is powered through low side control on pin 10 of the FCM. Under normal operating conditions, if the horn is pressed for longer than 30 seconds, the FCM will automatically deactivate the horn to prevent damage to it. The FCM will re-activate control of the relay after a 25 second cool-down period. This circuit is electronically controlled and continuously monitored for malfunctions. Front and rear blower relay RS with MTC Upon ignition on, the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus.The front blower relay and the rear blower relay, if equipped, are then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. RG with MTC Upon power up (Power switch on), the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus. The front blower relay is then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. Name Brand Speakers (NBS) relay The NBS relay operates through the vehicle bus interface between the radio and the FCM. When the radio is turned on, the radio sends a PCI Bus message to the FCM. The NBS relay is then powered on through low side control on pin 11 of the FCM. The relay supplies power to the amplified speaker, and ground is supplied through the radio. This circuit is electronically controlled and continuously monitored for malfunctions. Electronic Back Light (EBL) relay The rear defrost switch is part of the Automatic Temperature Control or A/C-Heater Control Module (Manual Temp). When the ignition switch is in the RUN position and the rear defrost switch is turned on, the ATC or A/C-Heater Control Module sends a PCI Bus message to the FCM. The EBL run only relay is then powered through low side control on pin 31 of the FCM. The relay provides the high side to the rear window defrost grid, and ground is attached to the vehicle body. The FCM will only allow the rear defrost to operate in the RUN position. This circuit is electronically controlled and continuously monitored for malfunctions. Adjustable Pedals Relay (Non-Memory) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2876 The Adjustable Pedals Relay is only on nonmemory Adjustable Pedals System equipped vehicles. The relay is supplied battery voltage from the IPM and is electronically controlled with a low side driver within the FCM. The relay is energized when the transmission is in reverse and when cruise control operation is engaged. This action disables the Adjustable Pedals System from movement. This circuit is continuously monitored for proper function. ELECTRICAL INPUTS Headlamp battery supplies 1 & 2 - 12 volt input on pins 1 and 2. Battery supply voltage for switching headlamp circuits only. Module battery supply - 12 volt input on pin 9. Battery supply voltage for all other FCM operations. Power ground - Ground source on pin 8 for all FCM operations. Ignition switch RUN or START position status - 12 volt input on pin 37. Allows the FCM to determine the ignition switch status for related FCM operations. PCI Bus - Approximately 7.5 volt input on pin 22. Allows the FCM to communicate with other modules on the vehicle bus. Stop lamp Switch status - 12 volt input on pin 44. Provides for brake shift interlock function. Horn Switch - Ground input on pin 17. Primary means for engaging the horn. Back-up switch - Ground input on pin 39. Input is converted to a PCI Bus status message for use by other modules. Wiper park switch - Ground input on pin 16. Used to determine park placement of wipers. Also used as feedback to FCM to determine correct operating mode of wipers. Washer fluid level switch - Ground input to pull-up on pin 18. Ground is switched into the circuit when washer bottle fluid level is low. Brake fluid level switch - Ground input to pull-up on pin 36. Ground is switched into the circuit when brake fluid level is low. Ambient temperature sensor - Resistive input to pull-up on pin 25. Corresponding voltage level is converted to a PCI Bus message for use by other modules on the bus. Right park lamp outage - 12 volt input on pin 21. Used to determine if right park lamp circuit is operating properly. Left park lamp outage - 12 volt input on pin 41. Used to determine if left park lamp circuit is operating properly. Battery IOD - 12 volt input on pin 20. The FCM enters a low power consumption mode when the ignition is turned OFF. This low current draw battery supply keeps the microprocessor functioning in the low power mode. Battery (+) connection detection - 12 volt input on pin 38. The battery connection on the PDC incorporates the use of an internal switch to determine if the connector is properly mated and the Connector Positive Assurance (CPA) is engaged. If the CPA is not properly engaged, a voltage on pin 38 will be interpreted as an unseated connector and a fault will set. Flash programming voltage - 20 volt input on pin 42. When a DRBIII(R) is connected and the proper flash reprogramming sequence is selected, the 20 volt signal will be applied through pin 42. Heating and A/C System AUTOMATIC TEMPERATURE CONTROL (ATC) MODULE USAGE CAUTION: Do not swap ATC Modules from vehicle to vehicle. Software versions differ between models and between model years. Installing a ATC Module with software that is incompatible for a given vehicle can result in either improper or failed HVAC system operation. SYSTEM AVAILABILITY - The ATC system is a Three-Zone Air Conditioning System. SYSTEM CONTROLS The ATC Module: - is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - provides an A/C request over the PCI Bus to the Powertrain Control Module (PCM) when compressor operation is desired. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2877 - for exports with diesel engines, provides a Cabin Heater activation request over the PCI Bus to the Front Control Module (FCM) when conditions are favorable for Cabin Heater operation. - uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - uses input from infrared (I/R) sensors, which measure surface temperature, to maintain occupant comfort levels. The I/R sensors are mounted in the instrument panel center bezel. - can be operated in a manual mode. - provides a blower relay on request over the PCI Bus to the Front Control Module (FCM) when blower operation is desired. - controls front blower operating speed, providing 10 speeds in manual mode and infinite speeds in automatic mode. - provides a cold engine blower lockout function. A Blower Speed Clamping feature minimizes occupant discomfort by controlling the amount of warm air coming out of the HVAC system should the Powertrain Control Module (PCM) disable A/C Compressor operation while the Automatic Temperature Control (ATC) is set in an automatic mode. The PCM disables the A/C compressor if the A/C pressure is too low, if the A/C pressure is too high, if engine overheating is immanent, or if an engine overheating condition exists. The ATC clamps the blower speed if the outside air temperature is greater than 50° F (10° C) and the PCM has disabled the A/C compressor. This means that the ATC will not adjust blower speed automatically when the clamping feature is enabled, e.g. if the clamping feature is enabled while in Auto Lo the blower will continue to run in low speed; if the clamping feature is enabled while in Auto Lo and the operator selects Auto Hi the blower will continue to run in low speed; if the clamping feature is enabled while in Auto Hi the blower will continue to run at the highest speed. In any case the operator can manually change the blower speed as desired. When diagnosing blower related symptoms verify that none of the above conditions for disabling the A/C compressor exist before diagnosing the blower circuits and components. - controls rear blower operating speed, providing 10 speeds in manual mode and infinite speeds in automatic mode. The separate front and rear Blower Motor Controllers operate as follows: When blower operation is desired, the Blower Motor Controller provides a 10.0 volt signal to the ATC Module over a control circuit. The ATC Module provides a variable duty cycle ground to the 10.0 volt signal based on input from the blower switch. When the blower switch is set to LO speed, the ATC Module provides a short duty cycle (less time grounding the signal voltage). As higher blower speeds are requested, the ATC Module increases the duty cycle (more time grounding the signal voltage). When the blower switch reaches HI speed, the duty cycle increases to where the signal pattern is almost a flat line (with brief voltage spikes). - controls the front and rear electric door actuators operation. A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The ATC Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the ATC Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. - activates and deactivates the Rear ATC Switch. The Rear ATC Switch (Three-Zone Only): - provides desired rear blower speed input to the ATC Module. - provides desired rear blend and mode door position input to the ATC Module. The Dual-Zone ATC system uses: - two front, two-wire electric blend door actuators. - one front, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. The Three-Zone ATC system uses: - two front, two-wire electric blend door actuators. - one front, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. - one rear, two-wire electric blend door actuator. - one rear, two-wire electric mode door actuator. System Relays: - The Integrated Power Module (IPM) houses and provides power to the A/C Clutch Relay, Front Blower Motor Relay, and Rear Blower Motor Relay. SYSTEM REVISIONS The 2005 ATC system remains mostly carryover from 2004. Revisions to the 2005 ATC system include: - all new version 0012 software. SYSTEM DIAGNOSTICS Fault detection is through active and stored Diagnostic Trouble Codes (DTC's) - DTC's are displayed the DRBIII(R). - Active DTC's are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTC's are those which occurred in the system since the ATC Module received the last "clear diagnostic info" message. The AC Cooldown Test: - is actuated with the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2878 - checks A/C system performance based on evaporator temperature sensor input. WARNING: DO NOT OPERATE THE DCHA IN AN ENCLOSED AREA SUCH AS A GARAGE THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS VENT THE DCHA's EXHAUST WHEN OPERATING THE DCHA. REFER TO VENTING THE DCHA's EXHAUST UNDER CABIN HEATER IN THE GENERAL INFORMATION PORTION OF THIS SECTION FOR PROPER EXHAUST VENTING INSTRUCTIONS. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. CAUTION: Do not activate the A/C Cooldown Test with the engine off. Failure to follow these instructions can result in internal damage to the DCHA Heater Module. - The FCM monitors the PCI bus for the Cabin Heater Activation request. The request carries the status bit that the FCM requires to activate it's Cabin Heater Assist Control output. This output is a low side driver (coming from FCM pin 15) which supplies a ground signal to the Cabin Heater (pin 5). When the Cabin Heater receives this ground signal input, it interprets this as an activation signal. - The FCM low side driver is also capable of diagnostic sensing. The driver will sense an open circuit when the driver is off, and will sense a short to voltage when the driver is on. The FCM will set DTC's for both of these types of faults. For additional information, refer to Cabin Heater under General Information and Diagnostic Procedures. - will not run the air conditioning portion of this test if ambient temperature is below 12° C (53° F). The forced Cabin Heater activation will occur even if the air conditioning portion of this test fails to initiate because AC Cooldown test criteria was not met. When activated, the DCHA will operate for approximately seven minutes. Three minutes to run and four minutes to purge. - will pass the air conditioning portion of this test if the evaporator temperature drops 6.7° C (20° F) within two minutes of starting this test. - messages (air conditioning related only) display on the DRBIII(R) after running this test. These messages will clear after paging back out of this test. Therefore, it is important to note all of the AC Cooldown test messages before doing so. - All Cabin Heater-related DTC's display under Cabin Heater, Read DTC's. - will cause the DELAY and Snowflake VF segments on the ATC to flash for 162 seconds (RG with DCHA only). If the air conditioning portion of this test fails, the DELAY and Snowflake VF segments will continue to flash until the vehicle is driven more than three miles. MANUAL TEMPERATURE CONTROL (MTC) Vehicle Compatibility For MTC Modules MODULE USAGE SYSTEM AVAILABILITY - Three different types of systems are currently available for these vehicles. Single-Zone Air Conditioning System - Dual-Zone Air Conditioning System - Three-Zone Air Conditioning System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2879 SYSTEM CONTROLS The A/C-Heater Control Module: - is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - provides an A/C request to the Powertrain Control Module (PCM) over the PCI Bus when compressor operation is desired. - uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - for exports with diesel engines, provides a Cabin Heater activation request to the Front Control Module (FCM) over the PCI Bus when conditions are favorable for Cabin Heater operation. - for RS vehicles, provides a blower relay on request to the FCM over the PCI Bus upon ignition on. - for RG vehicles, provides a blower relay on request to the FCM over the PCI Bus when the Power switch on the A/C-Heater Control Module is turned on. - controls front blower operating speed. For RS vehicles, the four speed settings are Low, M1, M2, and High. For RG vehicles the five speed settings are Low, M1, M2, M3, and High. - for RS vehicles uses the blower switch to control system on/off and blower speed. - for RS vehicles uses the rear wiper/washer switch to control rear wiper/washer operation. - for RS vehicles, provides a rear wiper on request to the Body Control Module (BCM) when rear wiper operation is desired. - for RS vehicles, provides a rear washer on request to the Body Control Module (BCM) when rear washer operation is desired. - controls EBL operation. - on three-zone systems, activates and deactivates the Rear A/C-Heater Control. - on three-zone systems, controls rear blower operating speed. The three speed settings are Low, Med, and High. - controls the front and the three-zone system rear electric door actuators operation. A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C - Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. On Three-Zone systems, the Rear A/C-Heater Control: - controls rear blower motor operating speed. The three blower speeds are Low, Med, and High. - provides desired rear blend and mode door position input to the A/C-Heater Control Module. The Single-Zone HVAC system uses: - one, two-wire electric blend door actuator. - one, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. The Dual-Zone HVAC system uses: - two, two-wire electric blend door actuators. - one, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. The Three-Zone HVAC system uses: - two front, two-wire electric blend door actuators. - one front, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. - one rear, two-wire electric blend door actuator. - one rear, two-wire electric mode door actuator. System Relays: - The Integrated Power Module (IPM) houses and provides power to the A/C Clutch Relay, Front Blower Motor Relay, and Rear Blower Motor Relay. SYSTEM REVISIONS The 2005 MTC system remains mostly carryover from 2004. Revisions to the 2005 MTC system include: SYSTEM DIAGNOSTICS Fault detection is through active and stored Diagnostic Trouble Codes (DTC's) - DTC's are displayed by the DRBIII(R). - Active DTC's are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTC's are those which occurred in the system since the A/C-Heater Control Module received the last "clear diagnostic info" message. The A/C Cooldown Test: - is actuated with the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2880 - checks A/C system performance based on evaporator temperature sensor input. - will not run if ambient temperature is below 12.7° C (55° F). - will pass if the evaporator temperature drops 6.7° C (20° F) within two minutes of starting the test. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - for RS vehicles will cause the Rear Wipe/Wash and A/C status indicators on the A/C-Heater Control Module to flash alternately while the test is running. - for RG vehicles will cause the PWR and A/C status indicators on the A/C - Heater Control Module to flash alternately while the test is running. The A/C status indicator will flash twice per second to indicate that the A/C Cooldown Test needs to be run. The A/C status indicator will stop flashing twice per second if either the A/C Cooldown Test returns passed, or if any button on the control is pressed, or if the ignition is cycled and the odometer shows greater than eight miles. The HVAC Door Recalibration function: - is actuated with the DRBIII(R) After completing HVAC Door Recalibration, the DRBIII(R) will the store the total span and the status of each door actuator. Selecting HVAC Door Cal Monitor in the System Tests will display this information. - homes and repositions door actuators. - monitors for door span faults on the actuator circuits. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - for RS vehicles will cause the Rear Wipe/Wash and RECIRC status indicators on the A/C-Heater Control Module to flash alternately while the test is running. - for RG vehicles will cause the PWR and RECIRC status indicators on the A/C - Heater Control Module to flash alternately while the test is running. The RECIRC status indicator will flash twice per second to indicate that the HVAC Door Recalibration Test needs to be run. The RECIRC status indicator will stop flashing twice per second if either the HVAC Door Recalibration Test returns passed, or if any button on the control is pressed, or if the ignition is cycled and the odometer shows greater than eight miles. The Actuator Circuit Test: - is actuated with the DRBIII(R). - monitors for shorted actuator circuits. - allows service to easily diagnose and troubleshoot up to three simultaneous shorts. - supplements the continuous diagnostics on the actuator drive system. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. When Performing the Actuator Circuit Test CAUTION: - Shorted rear door driver circuits can cause additional Actuator Circuit Test messages to set for circuits where no condition exists to cause a fault. - To ensure a proper diagnosis, repair all Short Too Complex messages first, all rear door driver circuit related messages second, all common door driver circuit related messages third, and all front door driver circuit related messages last. - The DRBIII(R) can display up to three Actuator Circuit Test messages at a time. After repairing each Actuator Circuit Test message, cycle the ignition switch, then rerun the Actuator Circuit Test to ensure no new messages exist. - The Short Too Complex message: indicates that a specific determination of which lines are shorted could not be made. - is caused by more than three drivers being shorted in the same direction. For example, four drivers all shorted to ground, or two or more drivers shorted with at least one driver shorted to ignition/battery and one driver shorted to ground. - Messages displaying: XXX Driver/Circuit Shorted to Ignition/ Battery will set on a per-driver basis. - XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. - the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together.When the test returns passed, then troubleshooting should proceed to clearing faults and running the HVAC Door Recalibration system test as a final check of system health. Instrument Cluster The Instrument Cluster receives and sends messages to other modules via the PCI bus circuit. The indicator lamps will illuminate briefly for a bulb check when the ignition is turned from off to run. All of the gauges receive their information via the PCI bus from the powertrain control module and body control module. The gauges and the LEDs are not individually replaceable thereby requiring complete replacement of the Instrument Cluster if a repair is necessary. In the event that the Instrument Cluster loses communication with other modules on the PCI bus, the cluster will display no bus in the VF display. The Trip/Reset button is used to switch the display from trip to total mileage. Holding the button when the display is in the trip mode will reset the trip Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2881 mileage. This button is also used to put the cluster into self-diagnostic mode. The odometer display uses blue-green vacuum fluorescent digital characters. On base models, the Instrument Cluster has three gauges: Speedometer, fuel and temperature.A red dot appears through openings in the Instrument Cluster face (P-R-N-D-2-1) to indicate the gear selected. With other models, the Instrument Cluster may also include a tachometer and use a vacuum fluorescent shift indicator. The high-line Instrument Cluster features Electroluminescent Illumination of the gauge faces (EL Panel). This feature eliminates the use of bulbs for ,gauge/panel lighting. In a manner similar to fluorescent lights, a/c voltage from an inverter integrated circuit chip is applied to the phosphorescent material, causing it to glow. The phosphorescent material is screen-printed onto flexible Mylar sheets that form the gauge faces. The odometer display and door/liftgate ajar indicators turn on when a door is opened to assist both the customer and service technician to view the odometer without turning the ignition on. On models with AutoStick, the display includes an O/D OFF indicator that is illuminated when the driver presses the Overdrive Off button on the transaxle shifter. INSTRUMENT CLUSTER SELF TEST 1. Depress and hold the Odometer Reset button. 2. Turn the ignition switch to on. 3. Release the Odometer reset button. The Instrument Cluster will illuminate all indicators and step the gauges through several calibration points.Also, the odometer will display any stored codes that may have set. Interior Lighting COURTESY LAMP CONTROL The body controller has direct control over all of the vehicle's courtesy lamps. The body computer will illuminate the courtesy lamps under any of the following conditions: 1. Any door ajar and courtesy lamp switch on the headlamp switch is not in the dome off position. 2. The courtesy lamp switch on the headlamp switch is in the dome on position. 3. A Remote Keyless Entry unlock message is received. 4. Driver door unlocked with key (with VTSS only). ILLUMINATED ENTRY Illuminated entry will be initiated when the customer enters the vehicle by unlocking the doors with the key fob, or with the key if the vehicle is equipped with vehicle theft alarm. Upon exiting the vehicle, if the lock button is pressed with a door open, illuminated entry will cancel when the door closes. If the doors are closed and the ignition switch is turned on, the illuminated entry also cancels. The illuminated entry feature will not operate if the courtesy lamp switch is in the dome off position. INTERIOR LIGHTING BATTERY SAVER If any of the interior lamps are left on after the ignition is turned off, the BCM will turn them off after 8 minutes. To return to normal operation, the courtesy lamps will operate after the dome lamp switch or door ajar switch changes state. The glove box and switched reading lamps require that the ignition be turned to the on/acc position. Memory System The memory system consists of power driver's seat, power mirror, adjustable pedals and radio presets. The Memory Seat/Mirror/Adjustable Pedals Module (MSMAPM) is located under the driver's seat. It receives input from the following: driver's manual 8-way seat switch, driver's seat position sensors, PCI bus circuits, and the power mirror sensors. The module uses these inputs to perform the following functions: position the driver's memory seat, both exterior mirrors (during recalls), both pedals, and send/receive the memory system information over the PCI bus. The Memory Set Switch is wired to the Body Control Module (BCM). A button (either #1 or #2) pressed on the set switch causes the BCM to send a message to the MSMAPM which in turn will send a motion status message back to the BCM. If the message from the MSMAPM indicates no current motion, the BCM will send a recal message to the module. The MSMAPM will set the seat, exterior mirror, pedals, and radio to the presets for the indicated driver. If any one of the memory controlled systems is inoperative from its manual switch, use the schematics and diagnostic information to correct the concern. This manual addresses the memory problems only and it is assumed there is not a basic component failure. POWER SEAT The memory power seat provides the driver with 2 position settings for the driver's seat. Each power seat motor is connected to the MSMAPM with two motor drive circuits. Each circuit is switched between battery and ground. By being able to bidirectionally drive the circuits, the MSMAPM controls the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2882 movement of the motors based on input from the power seat switch or from the position sensors when performing a memory recall. Each motor contains a potentiometer to monitor the seat position. To monitor the position of the motor, the MSMAPM sends out a 5-volt reference on the sensor supply circuit.The sensor is grounded back to the module on a common ground circuit. Based on the position of the sensor, the MSMAPM monitors the voltage change through the sensor on a separate signal circuit. The MSMAPM stores the input value of each of the four seat potentiometers in memory when the system requests a set. The driver can initiate a memory recall, using either the door mounted memory switch or the RKE transmitter (if the remote linked to memory feature is enabled via the EVIC). When initiated, the MSMAPM adjusts the four seat sensors (by using the motors) to match the memorized seat position data. For safety, the memory seat recall is disabled by the MSMAPM when the vehicle is out of park position or if the speed is not zero. Any obstruction to seat movement over a 2-second delay will cause the seat to stop moving in which case a stalled motor would be detected by the MSMAPM and the corresponding seat output would be deactivated. However, if the object obstructing the seat is removed, the seat will function normally again. MEMORY MIRROR The driver side view mirror contains vertical and horizontal bi-directional drive positioning motors and position sensors. The MSMAPM provides a 5-volt reference on the signal circuit to each position sensor. The sensors share a common ground circuit. The MSMAPM monitors the position of the mirror motors by measuring the voltage on each signal circuit. When a memory position is set, the MSMAPM monitors and stores the position of the outside mirror. The MSMAPM adjusts the mirror to the appropriate positions when a memory recall message is received from the RKE or is requested from the memory set switch. The power mirror switch during non-memory operation operates the mirror independently of the MSMAPM. Overhead Console COMPASS/TEMPERATURE MODULE, COMPASS/MINI-TRIP COMPUTER or ELECTRONIC VEHICLE INFORMATION CENTER The Compass/Temperature Module (CT), Compass/Mini-Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) is located in the overhead console. The CT provides the vehicle operator with only outdoor temperature and the compass heading. The CMTC or EVIC supplements the standard vehicle instrumentation. The CMTC and EVIC use a vacuum fluorescent (VF) display to supply the vehicle operator with a compass heading, outdoor temperature, average fuel economy, distance to empty, trip odometer, elapsed ignition on time, distance to service, warning messages, and service messages. The difference between a CMTC and an EVIC is that only the EVIC provides additional memory, feature programming, and warning messages. The EVIC is capable of displaying warning messages and memory system messages when the vehicle is equipped with memory systems. The EVIC also provides the interface to enable and disable vehicle programmable features when the vehicle is equipped with certain features. If equipped, the EVIC is also available with an integrated Universal Garage Door Opener (UGDO) known as HomeLink(R). The EVIC may also be equipped with up to 4 power door switches: ON/ OFF, Left Sliding Door, Right Sliding Door, and Liftgate. The CT function buttons are labeled C/T and US/M. The CMTC function buttons are labeled US/M, C/T, RESET, and STEP. The EVIC function buttons are labeled C/T, RESET, STEP, and MENU. The three UGDO buttons are labeled with dots to indicate the channel number. The BCM supplies most of the information displayed by the CMTC/EVIC. Display information, except for the internal compass function, is received over the PCI bus. The FCM supplies the ambient temperature sensor information via the PCI bus. The CMTC/EVIC sends and receives data over the PCI bus, communicating with the BCM, PCM, FCM, and the Instrument Cluster. Tire Pressure Monitoring System information is received from the SKREEM via PCI bus information. The tire pressure sensors are mounted to the vehicle wheels. For complete information, refer to the Tire Pressure Monitoring System section. VEHICLE INFORMATION DISPLAY The CMTC/EVIC provides the following functions: - Compass direction - Outside temperature - Elapsed ignition on time - Distance to empty - Average fuel economy - Trip odometer - Distance to service The EVIC will also display the following driver alert messages: - TURN SIGNAL ON (with vehicle graphic) - PERFORM SERVICE - DOOR OPEN (individual or multiple doors, with graphic) - LOW TIRE PRESSURE (when equipped) - ADJUSTABLE PEDAL DISABLED CRUISE ENGAGED (when equipped) - ADJUSTABLE PEDAL DISABLED VEHICLE IN REVERSE (when equipped) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2883 An audible chime or chimes will accompany any displayed warning messages. Chime requests with an OPEN message are dependent upon vehicle speed. The CT/CMTC/EVIC will not display information for any of the screens for which it did not receive the proper PCI bus data. Refer to the symptom list in the Overhead Console section for problems related to the CT/CMTC/EVIC. The CMTC/EVIC receives the following messages from the Body Control Module (BCM): - Verification of US/Metric status - VF display dimming brightness and exterior lamp status - Elapsed Ignition On Time data - Average Fuel Economy - Distance to Empty - Distance to service - Driver warning messages The CT/CMTC/EVIC receives the following messages from the Front Control Module (FCM): - Outside Temperature The CMTC/EVIC receives the following messages from the Powertrain Control Module (PCM): - Trip Odometer data - Vehicle Speed The EVIC receives the following messages from the Adjustable Pedal System Module (APS): - APS status warnings The CT/CMTC/EVIC receives the following messages from the Sentry Key Remote Electronic Entry Module (SKREEM): - Tire Pressure information The CMTC/EVIC transmits the following messages to the BCM: - Status Request: Beep, Reset, US/M Toggle - Current Display STEP BUTTON The STEP Button can be used in one of the following three ways: 1. To sequentially select one of seven displays or blank display in the following order: - Average Fuel Economy - Distance to Empty - Trip Odometer - Time Elapsed - Distance to Service Message - Off (Blank) 2. To set the magnetic variance zone when VARIANCE = X (X = 1 - 15) is indicated in the VF Display. 3. To select the displayed programmable feature setting. (When equipped.) MENU BUTTON (EVIC only) For complete information of the programmable features and memory messages. Use the MENU button to sequentially step the EVIC through the programmable features. MENU BUTTON (EVIC only) For complete information of the programmable features and memory messages.Use the MENU button to sequentially step the EVIC through the programmable features. RESET BUTTON The RESET Button has two different functions: 1. To clear the trip functions that may be reset 2. To enter and exit the diagnostic mode Pressing the RESET button once will clear the trip function that is currently being displayed (except Distance to Service) and the CMTC/EVIC will send a PCI bus beep request to the BCM. If the RESET button is pressed again within 3 seconds, the CMTC/EVIC will reset ALL of the trip functions and an additional beep request is sent to the BCM. The trip functions that may be reset are: - Average Fuel Economy - Trip Odometer - Elapsed Time Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2884 A reset will only occur if one of the trip functions that may be reset is currently being displayed. Pressing the RESET button for more than three (3) seconds resets the Distance to Service function while the Distance to Service message is being displayed. The CMTC/EVIC module will send a beep request to the BCM. Simultaneously pressing the RESET button and the STEP button while turning the ignition from Off to On will enter the CMTC/EVIC into the self-diagnostic mode. COMPASS/TEMPERATURE (C/T) BUTTON Actuating the Compass/Temperature Button (C/T) will cause the CMTC/EVIC to display the compass and temperature information. This function will operate from another traveler display or from the programmable feature mode. TRAVELER DISPLAY FUNCTIONS Using the STEP button will change the CMTC/ EVIC between modes of operation and display the appropriate information according to data received from the PCI Bus. COMPASS/TEMPERATURE The CMTC/EVIC simultaneously displays the compass reading and the outside temperature. Outside temperature information is received via the PCI bus from the FCM. The CMTC/EVIC module internally senses and calculates the compass direction. COMPASS OPERATION - ALL Upon ignition on, if the calibration information stored in the CMTC memory is within the normal range, the CMTC will perform in slow Auto-Cal mode. In slow Auto-Cal mode, the CMTC continuously compensates for the slowly changing magnetic field of the vehicle. The compass module detects changes in the vehicle magnetism and makes appropriate internal corrections to ensure proper displayed direction. However, if the calibration information stored in the CMTC memory is not within the normal range at ignition on, the CMTC will enter fast Auto-Cal. CAL is displayed along with the temperature. Auto activation of the fast Auto-Cal mode will also occur when the CMTC is subjected to high magnetic field strength levels, which cause all compass readings to be erroneous for a continuous period of five (5) minutes. During fast Auto-Cal, CAL will be displayed along with the temperature. Fast Auto-Cal can also be performed manually, by pressing and holding the RESET button for 10 seconds during the Compass/Temperature display mode. SETTING MAGNETIC ZONE VARIANCE Variance is the difference between magnetic North and geographic North. For proper compass function, the correct variance zone must be set. Refer to the Zone Variance map for the correct zone. Follow these steps to check or change the variance zone: CMTC/EVIC: - The ignition switch must be in the On position and the CMTC/EVIC display must not be blank. - If the compass/temperature data is not currently being displayed, momentarily press and release the C/T button to display compass/temp information. - Press and hold the RESET button (approximately 5 seconds) until VARIANCE = XX is displayed. The CMTC/EVIC will display the variance zone stored in memory and the word VARIANCE. - Use the RESET button to select the proper variance zone number, 1 through 15. - After selecting the proper zone number, momentarily press and release the RESET button. The variance zone is then stored in the memory and the CMTC/EVIC returns to normal operation. CT: - The ignition switch must be in the On position and the C/T display must not be blank. Press and hold the C/T and US/M buttons (approximately 5 seconds) until VARIANCE = XX is displayed. The C/T will display the variance zone stored in memory and the word VARIANCE. - Use the US/M button to select the proper variance zone number, 1 through 15. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2885 - After selecting the proper zone number, momentarily press and release the C/T button. The variance zone is then stored in the memory and the C/T returns to normal operation. COMPASS CALIBRATION The compass module has 2 types of auto calibration; slow-cal and fast-cal. Slow-cal ensures that during normal vehicle operation th0e compass performs auto-calibration functions to keep the compass sensors in their proper operating range. Whenever the ignition is On and the CT/CMTC/ EVIC receives PCI bus data indicating that engine RPM is greater than zero, auto-calibration is performed continuously. If the calibration information stored in the compass module memory is not within the normal range after a power-up cycle, the compass will display CAL. The CT/CMTC/EVIC will enter into the fast-cal mode until calibration is complete. To enter the compass into Manual Calibration mode, perform the following steps: - Drive the vehicle to an area away from any large metal objects or overhead power lines. - Ensure that the proper variance zone is selected. See "Setting Magnetic Zone Variance". - The ignition switch must be in the On position and the CMTC/EVIC display must not be blank. - Press the C/T button to view the Compass/ Temperature display. - Press and hold the RESET button (approximately 10 seconds) until CAL is displayed, then release the button. - Drive slowly, less than 5 MPH (8 KPH) in at least 1 complete 360-degree circle. - CAL will remain illuminated to alert the driver that the compass is in the calibration mode. - After calibration is complete, CAL will turn off. NOTE: For C/T Manual Calibration, perform the same procedure as above, but press and hold the C/T and US/M buttons until CAL is displayed. If the compass appears blank, unable to be calibrated, or the compass displays false indications,the vehicle must be demagnetized. SELF-CHECK DIAGNOSTICS The CT/CMTC/EVIC is capable of performing a diagnostic self check on its internal functions. Diagnostics may be performed using a DRBIII(R) or by using the following procedure: 1. For CMTC/EVIC: With the ignition switch in the OFF position, depress and hold the RESET and the STEP buttons. For CT: With the ignition switch in the OFF position, depress and hold the C/T and the US/M buttons. 2. Turn the ignition switch to the ON position. 3. Continue to hold both buttons until the software versions are displayed, then release the buttons. 4. All of the VFD segments will illuminate for 2-4 seconds. Check for segments that do not illuminate or illuminate all the time. 5. When the self-check is complete the EVIC will display one of the following messages: - PASS SELF TEST - FAILED SELF TEST - NOT RECEIVING J1850 MESSAGE When the self-check is complete the CT/CMTC will display one of the following messages: - PASS - FAIL - BUS 1. To exit the self-check mode: For the CMTC/EVIC: Depress the STEP or RESET button, or cycle the ignition switch and the CMTC/EVIC will return to normal operation. For the C/T: Depress the C/T or US/M button, or cycle the ignition switch and the CT will return to normal operation. If a Communication fault is displayed, refer to the symptom list. If a FAIL or FAILED is displayed, the CT/CMTC/EVIC must be replaced. AMBIENT TEMPERATURE SENSOR Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2886 The ambient air temperature is monitored by the FCM and displayed by the CT/CMTC/EVIC. The FCM receives a hardwire input from the ambient temperature sensor (ATS). The ATS is a variable resistor that operates on a 5-volt reference signal circuit hardwired from the FCM. The resistance in the ATS changes as the outside temperature rises or falls. The FCM senses the change in reference voltage through the ATS resistor. Based on the resistance of the ATS, the FCM is programmed to correspond to a specific temperature. The FCM stores and filters the ambient temperature data and transmits this data to the CMTC/EVIC via the PCI Bus. The ATS cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. AMBIENT TEMPERATURE SENSOR FAULT CODES The outside temperature function is supported by the ambient temperature sensor (ATS), a signal and ground circuit hardwired to the FCM, and the CMTC/EVIC display. If the ATS sense circuit is shorted to ground, the temp display will be 54° C (130° F) to indicate SHORT circuit condition. If the ATS sense circuit is open, the temp display will be -40° C (-40° F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the CMTC/EVIC VFD can be tested. The ATS is supported by the FCM. Ambient Temperature Sensor DTC's will be recorded in the FCM. The ATS can be diagnosed using the following Sensor Test. Test the ATS circuits using the diagnostics in the Body Diagnostic Procedures Manual. If the CMTC/EVIC passes the self-test, and the ATS, the circuits, and PCI bus communications are confirmed to be OK, but the CMTC/EVIC temperature display is inoperative or incorrect, replace the FCM. AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: - 0° C (32° F) Sensor Resistance = 29.33 - 35.99 Kilohms - 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kilohms - 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kilohms - 25° C (77° F) Sensor Resistance = 9.12 - 10.86 Kilohms 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kilohms - 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance values are not OK, replace the Sensor. HOMELINK(R) UNIVERSAL TRANSMITTER If equipped, HomeLink(R) Universal Transmitter is integrated into the overhead console. For added security it will operate home security systems that use coded signals known generically as Rolling Codes. The overhead console display provides visual feedback to the driver, indicating which HomeLink(R) transmitter channel button is being pressed. The HomeLink(R) can learn and store up to three separate transmitter radio frequency codes to operate garage door openers, security gates, and security lighting. The HomeLink(R) buttons are marked with one, two, or three dots. For complete information. TIRE PRESSURE MONITORING SYSTEM (TPMS) If equipped with the Tire Pressure Monitoring System (TPMS), each of the vehicles four wheels will have a valve stem with a pressure sensor and radio transmitter built in. Signals from the tire pressure Sensor/Transmitter are received and interpreted by the Sentry Key Remote Entry Module (SKREEM). Using the DRBIII(R), go to ANTI-THEFT for the SKREEM data. A Sensor/Transmitter in a mounted wheel will broadcast an RF frequency indicating its pressure once per minute when the vehicle is in drive mode. To activate the Sensor/Transmitter operation, the required SKREEM speed is 13 mph (20 km/h). Each Sensor/Transmitters broadcast is uniquely coded so that the SKREEM can monitor the states of each Sensor/Transmitter on the vehicle. The SKREEM TPMS does not use a magnet to relearn, it automatically learns while driving after a SKREEM or a Sensor/Transmitter has been replaced. TRAINING THE SKREEM If a Sensor/Transmitter is replaced, the vehicle has to be parked for at least 15 minutes for the system to be ready to learn the new Sensor/Transmitter ID code. The vehicle then must be driven for a minimum of five minutes with a minimum continuous speed above 13 mph (20 km/h). The system will learn the new Sensor/Transmitter and clear the DTC's automatically. The Sensor/ Transmitters are programmed at the assembly plant in this clockwise orientation: Sensor/Transmitter 1 = Left Front Sensor/Transmitter 2 = Right Front Sensor/Transmitter 3 = Right Rear Sensor/Transmitter 4 = Left Rear NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2887 1. If one or all Sensor/Transmitters cannot be trained, check for and avoid RF interference. 2. If one Sensor/Transmitter still cannot be trained, replace it and retry. 3. If all Sensor/Transmitters still fail to train, replace the SKREEM. PRESSURE THRESHOLDS The SKREEM will monitor the tire pressure signals from the Sensor/Transmitters and determine if any tire has gone below the low-pressure or above the high-pressure thresholds. Refer to the tables below: Low Tire Pressure Thresholds High Tire Pressure Thresholds *Tolerance ±6.9 kPa (1 PSI) ACTIVE FAULT AND SYSTEM ALERTS An active fault will be triggered when a system failure has been detected. When this occurs, the Instrument Cluster will illuminate the TPMS indicator and the SKREEM will store the fault code. An alert will be triggered when a tire pressure has gone below or above the set threshold pressure. When this occurs, the Instrument Cluster will flash the TPMS indicator. The SKREEM will request a secondary message to be displayed on the EVIC (if equipped). Only when a tire pressure has gone below the set threshold pressure will the SKREEM request the TPMS indicator to flash and display the EVIC message (if equipped). When a high pressure alert occurs, only the EVIC message will be displayed. This action will be displayed as long as the alert condition is active. Park Assist System The Park Assist System display activates an audible tone that changes from intermittent to continuous as the final two Light Emitting Diodes (LED's) are illuminated on one side or both sides of the display. The system detection length from the rear of the vehicle is 0.3 meters to 1.5 meters. This area extends around the rear side of the vehicle.The system detection height from the ground is 0.2 meters to about 1.5 meters. The radio mutes when the system activates its audible tone. When the driver selects Reverse or Neutral the system scans for objects behind the vehicle using four sensors located in the rear bumper. Objects can be detected from up to 1.5 meters. A warning display above the rear window provides both visible and audible warnings indicating the range of the object. The system is active only when the vehicle is in reverse or neutral for vehicle speeds less than 16 Km/h (10 mph). If the vehicles Parking/Emergency Brake is applied, the system is deactivated. The display contains two sets of yellow and red Light Emitting Diode's (LED's) that the driver can see in the rear view mirror. Each side of the vehicle has its own warning LED's. The system provides a visual warning by illuminating one or more yellow LED's as the vehicle gets closer to the object. As the vehicle continues to approaches the object, one red LED is illuminated and the system emits a series of short beeps. The tone will remain constant and both red LED's are illuminated once the vehicle is within 12 inches (30.5 cm) of the object. The system can be turned ON or OFF through the Electronic Vehicle Information Center (EVIC) when the vehicle is in PARK. If the park assist system is turned OFF, a single chime will sound and the EVIC will display the following message REAR PARK ASSIST OFF, when the vehicle is in reverse. - Ensure that the rear bumper is free of dirt and debris to keep the system operating properly. - Jackhammers, large trucks, and other vibrations could affect the performance of the system. - Ensure that the parking brake is not applied. If Service Park Assist System appears in the EVIC after making sure the rear bumper is clean, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2888 proceed to diagnose the system using a scan tool and the appropriate diagnostic information. Power Door Lock System When the BCM receives input for a lock request from a door lock switch, RKE or cylinder lock switch (only with VTSS), it will turn the lock drivers on for a specified time of 375 msec. If the request is there beyond 375 msec, the BCM considers the door lock signal stuck. Once a door lock or unlock signal is stuck for longer than 10 seconds, the BCM will set a trouble code and the signal input is ignored until the stuck condition disappears. The door lock switches provide a variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond to that command. DOOR LOCK INHIBIT When the key is in the ignition and in any position and either front door is open, the door lock switches LOCK functions are disabled. The UNLOCK functions are still functional. This protects against locking the vehicle with the keys still in the ignition. The RKE key fob will still lock the doors as usual. After the key is removed from the ignition or the doors are closed, the power door locks will operate normally. AUTOMATIC DOOR LOCKS This feature can be enabled or disabled by using either the DRBIII(R) or the customer programming method. When enabled all the doors will lock when the vehicle reaches a speed greater than 18 MPH (29 KMH) and all the doors are closed. If a door is opened and the vehicle slows to below 18 MPH (29 KMH), the door locks will operate again once all doors are closed and the speed is above 18 MPH (29 KMH). REMOTE KEYLESS ENTRY (RKE) The RKE transmitter uses radio frequency signals to communicate with the SKREEM module. The SKREEM is on the PCI bus. When the operator presses a button on the transmitter, it sends a specific request to the SKREEM. In turn the SKREEM sends the appropriate request over the PCI Bus to the: - Body Control Module (BCM) to control the door lock and unlock functions, the arming and disarming of the Vehicle Theft Security System (if equipped), and the activation of illuminated entry. - Integrated Power Module (IPM) to activate the park lamps, the headlamps, and the horn for horn chirp. - Power Liftgate Module (PLGM) to control the liftgate operation (double press). - Power Sliding Door Module (PSDM) to control the sliding door operation (double press). After pressing the lock button on the RKE transmitter, all of the door locks will lock, the illuminated entry will turn off (providing all doors are closed), and the vehicle theft security system (if equipped) will arm. After pressing the unlock button, on the RKE transmitter, one time, the driver doorlock will unlock, the illuminated entry will turn on the courtesy lamps, and the vehicle theft security system system (if equipped) will disarm. After pressing the unlock button a second time, the remaining door locks will unlock. The EVIC or the DRBIII(R) can reprogram this feature to unlock all of the door locks with one press of the unlock button. If the vehicle is equipped with the memory system, the memory message will identify which transmitter (1 or 2) sent the signal. The SKREEM is capable of retaining up to 8 individual access codes (8 transmitters). If the PRNDL is in any position except park, the SKREEM will disable the RKE. The 3 or 6 button transmitter uses 1-CR2032 battery. The minimum battery life is approximately 5 years based on 20 transmissions a day at 84° F (25° C). Use the DRBIII(R) or the Miller Tool 9001 RF Detector to test the RKE transmitter. Use the DRBIII(R) or the customer programming method to program the RKE system. However, the SKREEM will only allow RKE programming when the ignition is in the on position, the PRNDL is in park position, and the VTSS (if equipped) is disarmed. PANIC FUNCTION Pressing the panic button on the RKE transmitter will cause the headlamp relay, the park lamp relay, and the horn relay to pulsate, which in turn will cause the exterior lamps to flash and the horn to sound intermittently. It will also cause the courtesy lamp relay to actuate, turning on the courtesy lamps. Pressing the panic button again stops the headlamps and the park lamps from flashing and the horn from sounding. However, the courtesy lamps will remain on until either the BCM times out lamp operation or until the ignition is turned on. The panic feature operates for three minutes at a time, unless the operator cancels it, or the ignition is turned on. Actuating the headlamp, horn, park lamps, and courtesy lamps with the DRBIII(R) will verify if the circuits and the Integrated Power Module are OK. If the panic feature is still inoperable with all transmitters, it will be necessary to replace the SKREEM. If the function is inoperable with just one transmitter, then replace only that transmitter. ROLLING CODE The rolling code feature changes part of the transmitter message each time that it is used. The transmitter message and the receiver message increment together. Under certain conditions with a rolling code system (pressing a button on the RKE transmitter over 255 times outside the receiver range, battery replacement, etc.), the receiver and transmitter can fall out of synchronization. NOTE: The lock function works from the RKE transmitter even in an out of synchronization condition and therefore it could be verified by pressing the LOCK button on the RKE integrated key. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2889 To resynchronize, press and release the UNLOCK button on the RKE transmitter repeatedly (it may take up to eight cycles) while listening carefully for the power door locks in the vehicle to cycle, indicating that resynchronization has occurred. PROGRAMMABLE DOOR LOCK FEATURES - The RKE can be changed to unlock all doors with one press - The Automatic Door Locks can be enabled/ disabled - Auto Unlock on Exit can be enabled/disabled - RKE horn chirp on lock can be enabled/disabled - RKE optical chirp (turn signal lamps) can be enabled/disabled - Program a new RKE transmitter. - RKE linked to memory (if equipped with memory system) enabled/disabled (DRBIII(R) only). Allows memory to be operable only from the driver door switch. Rear Window Defog/Heated Mirror The defroster button located on the HVAC control controls the rear window defogger and the heated side view mirrors. When the defroster button is pushed, the HVAC control sends a bus message over the PCI bus to the Front Control Module (FCM) which controls the Rear Window Defogger relay. The defroster LED will illuminate when the defroster function is on. The defroster will function for 10 minutes or can be cycled off sooner by pressing the defroster button again. Vehicle Theft Security System The Vehicle Theft Security System (VTSS) is part of the Body Control Module (BCM). The BCM monitors the vehicle doors, liftgate (export only), hood (export only), and the ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps and the VTSS indicator lamp. The VTSS does not prevent engine operation, this is done with the Sentry Key Remote Entry Module (SKREEM). The VTSS indicator lamp will flash for approximately 15 seconds during the arming process. If there is no interruption during the arming process, upon completion the VTSS indicator lamp will flash at a slower rate. When the BCM receives an input to trigger the alarm, the BCM will control the outputs of the headlamps, horn, and VTSS lamp for approximately 15 minutes. Arming (Active and Passive) Active arming occurs when the ignition key is removed, the RKE transmitter or door key cylinders are used to lock the vehicle doors, whether the doors are open or closed. The arming process is complete only after all doors are closed. Passive arming occurs when the ignition key is removed, the driver door is opened, and the doors are locked with the power door lock switch, and the door is closed. Disarming (Active and Passive) Active disarming occurs when the RKE transmitter is used to unlock the vehicle doors. This disarming will also halt the alarm once it has been activated. Passive disarming occurs upon normal vehicle entry (unlocking driver door with the key) or turning the ignition switch on with a valid ignition key. This disarming will also halt the alarm once it has been activated. Tamper Alert The VTSS tamper alert will sound the horn three times upon disarming after an initial alarming has occurred to indicate a tamper condition has occurred. Manual Override The system will not arm if the doors are locked using the manual lock control or if the locks are actuated by an inside occupant after the doors are closed. Diagnosis For complaints about the Vehicle Theft Alarm triggering on its own, use the DRBIII(R) and read the Last VTSS Cause status. Arming Before arming, all doors, liftgate, and the hood must be completely closed. The system can only be armed by locking the doors with the RKE transmitter. Disarming To disarm the alarm system, use the RKE transmitter or turn the ignition on with a valid ignition key. This will also halt the alarm once it has been activated. NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes on after ignition on and stays on, the PCI Bus Communication with the powertrain Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2890 control module has possibly been lost. Power Folding Mirrors The power folding mirrors are powered to two positions: folded and unfolded. The driver may choose fold or unfold with a switch that is located on the right side of the steering column. The folding mirror switch grounds a sense wire that comes from the Body Control Module when it is placed in the fold position. The mirrors will move to the position designated by the switch whether the ignition switch is the On or Off position and both front doors are closed. When the Power Folding Mirror switch is left in the fold position during a vehicle exit the mirrors will automatically unfold then refold after both front doors are closed. This is to prevent mirror contact with either front door when opened. When opening either front door, the Body Control Module will unfold the mirrors in the following manner depending on which front door is opened. If the driver door is opened, only the driver side mirror will unfold. If the passenger door is opened, both mirrors will unfold. The passenger mirror is prevented from unfolding when the driver's door is opened by the Passenger Folding Mirror Relay, which opens the driver circuit to the passenger side mirror. Power Liftgate System POWER LIFTGATE The power liftgate (PLG) system is activated through the use of the following: remote keyless entry (RKE), overhead console switches, outside liftgate handle switch or the DRBIII(R). These inputs are hardwired to the body control module (BCM) and can be monitored with a diagnostic tool. The BCM will send the message via PCI bus to the power liftgate module (PLGM). The liftgate must be in the full open or full closed position to operate. Once the BCM sends a button activation message to the PLGM, the module shall read all inputs, outputs and vehicle conditions to determine whether it shall open, close or inhibit the PLG operation. Once the PLGM determines the vehicle conditions are safe for operation, the PLGM will initiate a chime for 2 seconds prior to the liftgate activation and 2 seconds during the open or close cycle. During an opening or closing cycle, the PLGM can detect an obstacle present should it meet sufficient resistance by the hall effect sensors (integrated in the gear motor assembly GMA).During an open cycle, multiple liftgate activations (RKE, overhead console, B pillar) are ignored until the liftgate reaches the full open position. However, during a close cycle, a 2nd liftgate activation (RKE, overhead console, B pillar) will reverse the liftgate to the full open position. If the engine is cranked during a power open/close the PLG will pause then resume after engine cranking. In addition, if the vehicle is placed in gear during an open cycle, the PLG shall reverse direction and begin closing. If the vehicle is placed in gear during a closing cycle, the PLG shall continue closing until fully closed. If the outside handle is activated during an open cycle, the PLG will become a full manual liftgate. If the outside handle is activated during a close cycle, the PLG shall reverse direction of travel to the full open position. DIAGNOSTIC FEATURES The PLG can be flashed on vehicle via PCI bus with a DRBIII(R) diagnostic tool. The DRBIII(R) can read all inputs, actuate all outputs, read module information, and read diagnostic trouble codes. As a reminder, some DTC's can be set during normal PLG operation. SYSTEM INHIBITORS 1. Battery voltage too high or too low (above 16 V, below 9.5 V) 2. Vehicle in gear 3. Vehicle speed > 0 mph/km/h 4. Outside temperature too high, above 143° F (62° C) or too low, below -12° F (-24° C). 5. O/H console lockout will inhibit the B pillar switches only. 6. Liftgate locked will inhibit all interior switches from opening (overhead console). A locked liftgate can be power closed. 7. Pinch Sensor switch stuck shall inhibit the power close feature. Power Sliding Door System POWER SLIDING DOOR The Power Sliding Door (PSD) system is activated through the use of the following: Remote Keyless Entry (RKE), overhead console switches, B pillar switches or the DRBIII(R). These inputs are hardwired to the body control module (BCM) and can be monitored with a diagnostic tool. The BCM will send the message via PCI bus to the power sliding door module (PSDM). The sliding door must be in the full open or full closed position to operate. Once the BCM sends a button activation message to the PSDM, the module shall read all inputs, outputs and vehicle conditions to determine whether it shall open, close or inhibit the PSD operation. During an opening or closing cycle, the PSDM can detect an obstacle present should it meet sufficient resistance by the hall effect sensors (integrated in the drive motor). During an open cycle, multiple door activations (RKE, overhead console, B pillar) are ignored until the door reaches the full open position. However, during a close cycle, a 2nd door activation (RKE, overhead console, B pillar) will reverse the door to the full open position. If the engine is cranked during a power open/close the PSD will pause then resume after engine cranking. In addition, if the vehicle is placed in gear during an open cycle, the PSD shall reverse direction and begin closing. If the vehicle is placed in gear during a closing cycle, the PSD shall continue closing until fully closed. If the inside or outside handle is activated during an open or close cycle, the PSD will become a full manual sliding door. The child lockout is mechanical only and has no effect on the B-pillar switch as it did in previous models. There is only one part number for the power sliding door module (PSDM). The driver sliding door harness has an additional ground circuit which will Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2891 identify it as the driver side. This eliminates the need for a left and a right side module. DIAGNOSTIC FEATURES The PSDM can be flashed on vehicle via PCI bus with a DRBIII(R) diagnostic tool. The DRBIII(R) can read all inputs, actuate all outputs, read module information, and read diagnostic trouble codes. As a reminder, some DTC's can be set during normal PSD operation. SYSTEM INHIBITORS 1. Battery voltage too high or too low (above 16 V, below 9.5 V) 2. Vehicle in gear 3. Vehicle speed > 0 mph/km/h 4. O/H console lockout will inhibit the B pillar switches 5. Doors locked will inhibit all interior switches from opening (Overhead Console, B Pillar). A locked sliding door can be power closed. Wiper System FRONT WIPER The front wiper/washer system consists of the following features: lo-hi-speed, mist wipers, intermittent wipers and wipe after wash. The front wiper system is only active when the ignition switch is in the RUN/ACC position. The vehicle operator selects the front wiper function using the front wiper switch (a resistive multiplexed stalk switch) which is integral to the Multi-Function Switch. The front wiper switch is hardwired to the Body Control Module (BCM). Upon receiving a wiper switch signal, the BCM sends a PCI Bus message to the Front Control Module (FCM). The FCM controls the ON/ OFF relay, the HIGH/LOW relay and the front and rear washer pump motors. The Wiper system utilizes the BCM to control the on/off and hi/low relays for the low and hi speed wiper functions, intermittent wiper delay as the switch position changes, pulse wipe, wipe after wash mode and wiper motor functions. The BCM uses the vehicle speed input to double the usual delay time below 10 MPH (16 KPH). SPEED SENSITIVE INTERMITTENT WIPE MODE There are 5 individual delay time settings with a minimum delay of 1.7 seconds to a maximum of 18.4 seconds. When the vehicle speed is under 10 MPH (16 KPH), the delay time is doubled, providing a delay range of 3.4 seconds to 36.8 seconds. PULSE WIPE When the wiper is in the off position and the driver presses the wash button for more than 0.062 seconds, but less than 0.5 seconds,2 wipe cycles in low speed mode will be provided. PARK AFTER IGNITION OFF Because the wiper relays are powered from the battery, the BCM can run the wipers to park after the ignition is turned off. WIPE AFTER WASH When the driver presses the wash button for over 0.5 seconds and releases it, the wiper will continue to run for 2 additional wipe cycles. REAR WIPER The rear wiper/washer system consists of the following features: mist wipers, intermittent wipers and wipe after wash. The rear wiper system is only active when the ignition switch is in the RUN/ACC position. The vehicle operator selects the rear wiper function using one of the three buttons on the dash mounted rear wiper switch. The rear wiper switch is hardwired to the Body Control Module (BCM). Upon receiving a wiper switch signal, the BCM provides 12 volts to the rear wiper motor. Rear washer occurs when the BCM receives a rear washer switch ON input. The BCM sends a PCI Bus message to the FCM requesting rear washer on. The FCM activates the rear washer by providing a ground for the rear washer motor. SPEED SENSITIVE INTERMITTENT WIPE MODE The delay setting of the rear wiper system is based solely on the vehicle speed. The delay time is defined as the amount of time from the start of a wipe to the beginning of the next wipe. The rear wiper system delay time is based on the following: 7.75 - (MPH x 0.05) = Seconds delay Examples:At zero (0) MPH the delay is 7.75 seconds. At 100 MPH the delay is 2.75 seconds. WIPE AFTER WASH When the driver presses the wash button for over 1.5 seconds and releases it,the wiper will continue to run for 2 additional wipe cycles. Telecommunications HANDS FREE PHONE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 2892 OVERVIEW The vehicle telecommunications system consists of a Hands Free Module, Rear View Mirror, and a Blue-tooth Hands Free Profile enabled cell phone. The system allows vehicle occupants to use voice recognition technology to make, receive and screen phone calls without physically handling a cell phone. The system has a programmable phone book that can prevent the vehicle operator from becoming distracted searching for a specific number. Seven different wireless phones can be programmed to operate each individual system. Each of the seven phones is given a rank of priority when programmed. OPERATION Incoming phone messages are transmitted to the vehicle occupants through the vehicles audio system when the ignition is on and the wireless phone is on. Upon receiving the signal from an incoming phone call, the vehicle audio system will fade out the current CD/DVD or radio output. The vehicle occupants are then directed to accept or reject the call.Outgoing audio messages are received through the microphone located in the rearview mirror then transmitted via hardwire to the Hands Free Module and finally transmitted through the wireless phone. Volume of the voice prompts and incoming conversation is controlled using the vehicles radio audio controls and steering wheel controls if equipped. The rear view mirror contains a Phone Switch, Voice Recognition Switch and a microphone. The rear view mirror transmits these inputs via hardwired circuits to the Hands Free Module. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Air Bag System Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Any Station Preset Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2895 Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2896 POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Test 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2897 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Pause/Play Switch Inoperative Test 1 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2898 Test 1 SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Remote Radio Controls Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2899 Test 4 - 7 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2900 Test 8 - 9 SYMPTOM REMOTE RADIO CONTROLS INOPERATIVE POSSIBLE CAUSES - Open radio control MUX circuit at the switch - Open radio control MUX return circuit at the switch - Remote radio switch - Body control module - internal short - Open clockspring - Open radio control MUX circuit - Open radio control MUX return circuit - Body control module - open internal Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2901 Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2902 POSSIBLE CAUSES - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure ATC Head LED(s)/Backlighting Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2903 Test 1 - 3 Test 4 - 5 SYMPTOM ATC HEAD LED(S)/BACK LIGHTING INOPERATIVE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2904 POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - ATC - LED(s) inoperative - ATC - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2905 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2906 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2907 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2908 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2909 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM FUSE #10 - Fused front blower motor relay output circuit shorted to ground - Blower motor shorted to ground - Front blower power module shorted to ground - Ground circuit open - Blower motor control circuit shorted to voltage - Blower motor control circuit open - Front blower power module open - Automatic temperature control module open - Check blower motor operation - Front blower power module open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2910 Test 1 Test 2 SYMPTOM FRONT BLOWER RUNS AT ONLY ONE SPEED Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2911 POSSIBLE CAUSES - Blower motor control circuit shorted to ground - Automatic temperature control module - Front blower power module HVAC System Test Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2912 Test 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2913 Test 6 Test 7 SYMPTOM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2914 HVAC SYSTEM TEST POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active ATC DTC's - Check for AC cooldown test fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear ATC Switch LED(s)/Backlighting Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2915 Test 4 - 5 SYMPTOM REAR ATC SWITCH LED(S)/BACK LIGHTING INOPERATIVE POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - Rear ATC switch - LED(s) inoperative - Rear ATC switch - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2916 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2917 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2918 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2919 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2920 Test 15 - 16 SYMPTOM REAR BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM Fuse #12 - Fused rear blower relay output circuit shorted to ground - Blower motor shorted to ground - Rear blower motor power module shorted to ground - Ground circuit open - Rear blower motor control circuit shorted to voltage - Rear blower motor control circuit open - Rear blower motor power module open - Automatic temperature control module open - Check blower motor operation - Rear blower motor power module open - IPM - open circuit - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2921 Test 1 Test 2 SYMPTOM REAR BLOWER RUNS AT ONLY ONE SPEED POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2922 - Rear blower motor control circuit shorted to ground - Automatic temperature control module - Rear blower motor power module Chime Inoperative Test 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE POSSIBLE CAUSES - Use DRB to actuate chime - Chime driver circuit - open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2923 - Chime driver circuit - short to ground - Chime driver circuit - short to voltage - Instrument cluster - BCM Key In Ignition and Drivers Door Open Chime Not Operating Properly Test 1 - 3 SYMPTOM KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME NOT OPERATING PROPERLY POSSIBLE CAUSES - DRB chime actuator - Driver door ajar status - Ignition switch - Body control module Vehicle Speed Warning Chime Problem Test 1 SYMPTOM PROBLEM WITH THE VEHICLE SPEED WARNING CHIME POSSIBLE CAUSES - Incorrect country code programmed in BCM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2924 - Body control module Left Front Door Ajar Switch Sense Circuit Open Test 1 - 4 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Left front door ajar switch ground circuit open - Left front door (lock motor) ajar switch - Left front door ajar switch sense circuit open - Body control module internal malfunction Left Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2925 Test 1 - 2 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left front door (lock motor) ajar switch shorted to ground - Left front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Left Sliding Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2926 Test 1 - 3 Test 4 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Left sliding door ajar switch sense circuit open - Left sliding door ajar switch sense circuit open - Body control module internal malfunction Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2927 - Left sliding door lock motor/ajar switch (latch assy). Left Sliding Door Ajar Switch Sense Circuit Shorted to Ground Test 1 - 3 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left sliding door lock motor/ajar switch shorted to ground - Left sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Left sliding door lock motor/ajar switch (latch assy). Liftgate Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2928 Test 1 - 4 SYMPTOM LIFTGATE AJAR CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Liftgate ajar switch ground circuit open - Liftgate ajar switch (cinch/release motor) - Liftgate ajar switch sense circuit open - Body control module internal malfunction Liftgate Ajar Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2929 Test 1 - 2 SYMPTOM LIFTGATE AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Liftgate ajar switch shorted to ground - Liftgate ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2930 Test 1 - 4 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Right front door ajar switch ground circuit open - Right front door (lock motor) ajar switch - Right front door ajar switch sense circuit open - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2931 Test 1 - 2 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right front door (lock motor) ajar switch shorted to ground - Right front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Sliding Door Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2932 Test 1 - 3 Test 4 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Right sliding door ajar switch sense circuit open - Right sliding door ajar switch sense circuit open - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2933 Right Sliding Door Ajar Circuit Shorted to Ground Test 1 - 3 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right sliding door lock motor/ajar switch shorted to ground - Right sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) A/C Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2934 Test 1 - 2 Test 3 SYMPTOM A/C STATUS INDICATOR FLASHING - MTC POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Blend/Mode/Recirc Door Operation Improper -- Dual & Three-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2935 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2936 Test 4 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2937 Test 7 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2938 Test 10 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER -- DUAL & THREE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Passenger blend door actuator/linkage/door - Driver blend door actuator/linkage/door - Recirculation door actuator/linkage/door - Rear mode door actuator/linkage/door - Rear blend door actuator/linkage/door Blend/Mode/Recirc Door Operation Improper --Single-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2939 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2940 Test 4 - 7 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER --SINGLE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Blend door actuator/linkage/door - Recirculation door actuator/linkage/door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2941 Front A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Test 4 SYMPTOM FRONT A/C - HEATER CONTROL ILLUMINATION INOPERATIVE -MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - A/C - heater control module - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2942 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2943 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2944 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2945 Test 11 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2946 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #10 - Fused front blower motor relay output circuit shorted to ground - Front blower motor resistor block shorted to ground - Front blower motor resistor block shorted to ground - Blower motor - Blower motor - A/C - heater control module - Ground circuit open - Blower motor high driver circuit open - Front blower motor resistor block open - Front blower motor resistor block open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Motor Speeds Incorrect - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2947 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2948 Test 3 - 5 SYMPTOM FRONT BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Blower motor driver circuit(s) shorted to ground - Blower motor driver circuit(s) shorted to voltage - Blower motor driver circuits shorted together - A/C - heater control module - speeds incorrect - Blower motor driver circuit(s) open - Blower motor resistor block - open speed HVAC System Test - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2949 Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2950 Test 5 Test 5 SYMPTOM HVAC SYSTEM TEST - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2951 POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active HVAC DTC's and system tests fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2952 Test 4 - 5 SYMPTOM REAR A/C - HEATER CONTROL ILLUMINATION INOPERATIVE - MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - Inoperative bulb - Ground circuit open - Rear blower rear control switch - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2953 Test 1 - 2 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2954 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2955 Test 11 - 14 SYMPTOM REAR BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #12 - Fused rear blower motor relay output circuit shorted to ground - Blower motor - Ground circuit open - A/C - heater control module - Check for power to rear blower motor - Blower motor - Rear blower high speed circuit open - Rear blower motor high circuit open - Rear blower motor resistor block - IPM - open circuit Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2956 - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Motor Speeds Incorrect - MTC Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2957 Test 3 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2958 Test 6 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2959 Test 10 SYMPTOM REAR BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to ground - A/C - heater control module - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to voltage - Rear blower motor front control feed circuit shorted to voltage - Rear blower driver CKT(s) shorted to rear blower front control feed CKT - Rear blower motor driver circuits shorted together - A/C - heater control module - Rear blower motor driver circuit(s) open - Rear blower motor resistor block Rear Blower Rear Control Switch INOP In One or More Speeds - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2960 Test 1 - 2 Test 3 SYMPTOM REAR BLOWER REAR CONTROL SWITCH INOP IN ONE OR MORE SPEEDS - MTC POSSIBLE CAUSES - Rear blower motor driver circuit(s) open - Rear blower rear control switch - Rear blower motor front control feed circuit open - A/C - heater control module Recirc Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2961 Test 1 - 2 Test 3 SYMPTOM RECIRC STATUS INDICATOR FLASHING - MTC TEST NOTE This symptom is diagnosed using the test A/C STATUS INDICATOR FLASHING - MTC. POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Any PCI Bus Indicator Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2962 Test 1 - 4 SYMPTOM ANY PCI BUS INDICATOR INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - No response - instrument cluster - No response - ECM / PCM - Indicator inoperative - Instrument cluster Seat Belt Indicator Always On Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2963 Test 1 SYMPTOM SEAT BELT INDICATOR ALWAYS ON POSSIBLE CAUSES - ACM seat belt indicator command present - Instrument cluster Overhead Console Test 1 - 4 SYMPTOM REPAIRING CMTC DISPLAYS DOUBLE DASH (- - ) IN TEMP DISPLAY POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2964 - No response - PCI BUS - powertrain control module - CMTC BUS message failure - Compass mini-trip computer - Ambient temperature sensor - PCM ambient air temperature sensor DTC present - CMTC internal Left Cylinder Lock Switch Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2965 Test 4 - 5 SYMPTOM LEFT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - left cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - left cylinder lock switch MUX short to voltage Remote Keyless Entry Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2966 Test 1 - 4 Test 5 - 6 SYMPTOM REMOTE KEYLESS ENTRY INOPERATIVE POSSIBLE CAUSES - DTC present - SKREEM DTC present - Test transmitter with tester - RKE transmitter inoperative - RKE transmitter not programmed - SKREEM module - RKE inoperative - SKREEM module - RKE inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2967 Right Cylinder Lock Switch Inoperative Test 1 - 3 Test 4 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2968 SYMPTOM RIGHT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - right cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - right cylinder lock switch MUX short to voltage Power Doors - Liftgate Test 1 - 4 SYMPTOM POWER LIFTGATE INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Power Doors - Sliding Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2969 Test 1 - 4 SYMPTOM POWER SLIDING DOOR INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Alarm Trips On Its Own Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2970 Test 1 - 4 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - Last VTSS cause - Attempt to trip alarm - Intermittent condition Left Front Door Does Not Trip VTSS Test 1 SYMPTOM LEFT FRONT DOOR DOES NOT TRIP VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2971 POSSIBLE CAUSES - Body control module - Check DRBIII(R) for driver door ajar response Left Sliding Door Does Not Trip VTSS Test 1 SYMPTOM LEFT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Monitor DRBIII(R) for left sliding door ajar status - Body control module Right Front Door Does Not Trip VTSS Test 1 SYMPTOM RIGHT FRONT DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for passenger door ajar response - Body control module Right Sliding Door Does Not Trip VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2972 Test 1 SYMPTOM RIGHT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for right rear door ajar response - Body control module VTSS Will Not Arm Test 1 - 3 SYMPTOM VTSS WILL NOT ARM POSSIBLE CAUSES - Check the VTSS status - Check for BCM DTC's and VTSS arming inhibitors - Check for PCI BUS communication of instrument cluster and SKIM - Body control module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2973 Body Control Module: Component Tests and General Diagnostics Six Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation Road Testing ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. WARNING: REASSEMBLE ALL COMPONENTS BEFORE ROAD TESTING A VEHICLE. DO NOT TRY TO READ THE DRBIII(R) SCREEN OR OTHER TEST EQUIPMENT DURING A TEST DRIVE. DO NOT HANG THE DRBIII(R) OR OTHER TEST EQUIPMENT FROM THE REARVIEW MIRROR DURING A TEST DRIVE. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIII(R) OR OTHER TEST EQUIPMENT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Vehicle Preparation For Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Glossary of Terms ABS antilock brake system ACT actuator APS adjustable pedals system ATC automatic temperature control BCM body control module BPS bladder pressure sensor BTS belt tension sensor CAB controller antilock brake CMTC compass/mini-trip computer CPA connector positive assurance DAB driver airbag DCHA diesel cabin heater assist (cabin heater) DLC data link connector DTC diagnostic trouble code DR driver EBL electric back lite (rear window defogger) ECM engine control module EVIC electronic vehicle information center FCM front control module GCC Gulf Coast Countries HE hall effect HFM hands free module HVAC heater ventilation, air conditioning IPM integrated power module KNB knee blocker airbag LDU lower drive unit LHD left hand drive MIC mechanical instrument cluster MTC manual temperature control MSMAPM memory seat/mirror/adjustable pedals module NAV navigation NGC next generation controller OBD on board diagnostics OCM occupant classification module OCS occupant classification system OCSVR occupant classification system verification required ODO odometer ORC occupant restraint controller PAB passenger airbag PASS passenger PCI Programmable Communication Interface (vehicle communication bus) PCM powertrain control module PDC power distribution center PLG power liftgate Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2974 PLGM power liftgate module PSD power sliding door PSDM power sliding door module PWM pulse width modulated RHD Right Hand Drive RKE remote keyless entry RX receive SAB seat airbag SBS seat belt switch SBT seat belt tensioner SKREEM sentry key remote entry module SQUIB also called initiator (located inside airbag) SRS supplemental restraint system TCM transmission control module TPMS tire pressure monitor system TX transmit VFD vacuum fluorescent display VTSS vehicle theft security system Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2975 Body Control Module: Testing and Inspection Diagnostic Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions Diagnostic Trouble Code Tests and Associated Procedures For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures Air Bag System Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Any Station Preset Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2976 Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2977 POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Test 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2978 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Pause/Play Switch Inoperative Test 1 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2979 Test 1 SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Remote Radio Controls Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2980 Test 4 - 7 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2981 Test 8 - 9 SYMPTOM REMOTE RADIO CONTROLS INOPERATIVE POSSIBLE CAUSES - Open radio control MUX circuit at the switch - Open radio control MUX return circuit at the switch - Remote radio switch - Body control module - internal short - Open clockspring - Open radio control MUX circuit - Open radio control MUX return circuit - Body control module - open internal Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2982 Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2983 POSSIBLE CAUSES - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure ATC Head LED(s)/Backlighting Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2984 Test 1 - 3 Test 4 - 5 SYMPTOM ATC HEAD LED(S)/BACK LIGHTING INOPERATIVE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2985 POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - ATC - LED(s) inoperative - ATC - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2986 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2987 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2988 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2989 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2990 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM FUSE #10 - Fused front blower motor relay output circuit shorted to ground - Blower motor shorted to ground - Front blower power module shorted to ground - Ground circuit open - Blower motor control circuit shorted to voltage - Blower motor control circuit open - Front blower power module open - Automatic temperature control module open - Check blower motor operation - Front blower power module open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2991 Test 1 Test 2 SYMPTOM FRONT BLOWER RUNS AT ONLY ONE SPEED Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2992 POSSIBLE CAUSES - Blower motor control circuit shorted to ground - Automatic temperature control module - Front blower power module HVAC System Test Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2993 Test 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2994 Test 6 Test 7 SYMPTOM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2995 HVAC SYSTEM TEST POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active ATC DTC's - Check for AC cooldown test fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear ATC Switch LED(s)/Backlighting Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2996 Test 4 - 5 SYMPTOM REAR ATC SWITCH LED(S)/BACK LIGHTING INOPERATIVE POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - Rear ATC switch - LED(s) inoperative - Rear ATC switch - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2997 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2998 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 2999 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3000 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3001 Test 15 - 16 SYMPTOM REAR BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM Fuse #12 - Fused rear blower relay output circuit shorted to ground - Blower motor shorted to ground - Rear blower motor power module shorted to ground - Ground circuit open - Rear blower motor control circuit shorted to voltage - Rear blower motor control circuit open - Rear blower motor power module open - Automatic temperature control module open - Check blower motor operation - Rear blower motor power module open - IPM - open circuit - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3002 Test 1 Test 2 SYMPTOM REAR BLOWER RUNS AT ONLY ONE SPEED POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3003 - Rear blower motor control circuit shorted to ground - Automatic temperature control module - Rear blower motor power module Chime Inoperative Test 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE POSSIBLE CAUSES - Use DRB to actuate chime - Chime driver circuit - open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3004 - Chime driver circuit - short to ground - Chime driver circuit - short to voltage - Instrument cluster - BCM Key In Ignition and Drivers Door Open Chime Not Operating Properly Test 1 - 3 SYMPTOM KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME NOT OPERATING PROPERLY POSSIBLE CAUSES - DRB chime actuator - Driver door ajar status - Ignition switch - Body control module Vehicle Speed Warning Chime Problem Test 1 SYMPTOM PROBLEM WITH THE VEHICLE SPEED WARNING CHIME POSSIBLE CAUSES - Incorrect country code programmed in BCM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3005 - Body control module Left Front Door Ajar Switch Sense Circuit Open Test 1 - 4 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Left front door ajar switch ground circuit open - Left front door (lock motor) ajar switch - Left front door ajar switch sense circuit open - Body control module internal malfunction Left Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3006 Test 1 - 2 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left front door (lock motor) ajar switch shorted to ground - Left front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Left Sliding Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3007 Test 1 - 3 Test 4 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Left sliding door ajar switch sense circuit open - Left sliding door ajar switch sense circuit open - Body control module internal malfunction Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3008 - Left sliding door lock motor/ajar switch (latch assy). Left Sliding Door Ajar Switch Sense Circuit Shorted to Ground Test 1 - 3 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left sliding door lock motor/ajar switch shorted to ground - Left sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Left sliding door lock motor/ajar switch (latch assy). Liftgate Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3009 Test 1 - 4 SYMPTOM LIFTGATE AJAR CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Liftgate ajar switch ground circuit open - Liftgate ajar switch (cinch/release motor) - Liftgate ajar switch sense circuit open - Body control module internal malfunction Liftgate Ajar Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3010 Test 1 - 2 SYMPTOM LIFTGATE AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Liftgate ajar switch shorted to ground - Liftgate ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3011 Test 1 - 4 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Right front door ajar switch ground circuit open - Right front door (lock motor) ajar switch - Right front door ajar switch sense circuit open - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3012 Test 1 - 2 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right front door (lock motor) ajar switch shorted to ground - Right front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Sliding Door Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3013 Test 1 - 3 Test 4 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Right sliding door ajar switch sense circuit open - Right sliding door ajar switch sense circuit open - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3014 Right Sliding Door Ajar Circuit Shorted to Ground Test 1 - 3 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right sliding door lock motor/ajar switch shorted to ground - Right sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) A/C Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3015 Test 1 - 2 Test 3 SYMPTOM A/C STATUS INDICATOR FLASHING - MTC POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Blend/Mode/Recirc Door Operation Improper -- Dual & Three-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3016 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3017 Test 4 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3018 Test 7 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3019 Test 10 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER -- DUAL & THREE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Passenger blend door actuator/linkage/door - Driver blend door actuator/linkage/door - Recirculation door actuator/linkage/door - Rear mode door actuator/linkage/door - Rear blend door actuator/linkage/door Blend/Mode/Recirc Door Operation Improper --Single-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3020 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3021 Test 4 - 7 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER --SINGLE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Blend door actuator/linkage/door - Recirculation door actuator/linkage/door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3022 Front A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Test 4 SYMPTOM FRONT A/C - HEATER CONTROL ILLUMINATION INOPERATIVE -MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - A/C - heater control module - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3023 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3024 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3025 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3026 Test 11 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3027 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #10 - Fused front blower motor relay output circuit shorted to ground - Front blower motor resistor block shorted to ground - Front blower motor resistor block shorted to ground - Blower motor - Blower motor - A/C - heater control module - Ground circuit open - Blower motor high driver circuit open - Front blower motor resistor block open - Front blower motor resistor block open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Motor Speeds Incorrect - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3028 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3029 Test 3 - 5 SYMPTOM FRONT BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Blower motor driver circuit(s) shorted to ground - Blower motor driver circuit(s) shorted to voltage - Blower motor driver circuits shorted together - A/C - heater control module - speeds incorrect - Blower motor driver circuit(s) open - Blower motor resistor block - open speed HVAC System Test - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3030 Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3031 Test 5 Test 5 SYMPTOM HVAC SYSTEM TEST - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3032 POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active HVAC DTC's and system tests fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3033 Test 4 - 5 SYMPTOM REAR A/C - HEATER CONTROL ILLUMINATION INOPERATIVE - MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - Inoperative bulb - Ground circuit open - Rear blower rear control switch - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3034 Test 1 - 2 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3035 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3036 Test 11 - 14 SYMPTOM REAR BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #12 - Fused rear blower motor relay output circuit shorted to ground - Blower motor - Ground circuit open - A/C - heater control module - Check for power to rear blower motor - Blower motor - Rear blower high speed circuit open - Rear blower motor high circuit open - Rear blower motor resistor block - IPM - open circuit Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3037 - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Motor Speeds Incorrect - MTC Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3038 Test 3 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3039 Test 6 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3040 Test 10 SYMPTOM REAR BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to ground - A/C - heater control module - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to voltage - Rear blower motor front control feed circuit shorted to voltage - Rear blower driver CKT(s) shorted to rear blower front control feed CKT - Rear blower motor driver circuits shorted together - A/C - heater control module - Rear blower motor driver circuit(s) open - Rear blower motor resistor block Rear Blower Rear Control Switch INOP In One or More Speeds - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3041 Test 1 - 2 Test 3 SYMPTOM REAR BLOWER REAR CONTROL SWITCH INOP IN ONE OR MORE SPEEDS - MTC POSSIBLE CAUSES - Rear blower motor driver circuit(s) open - Rear blower rear control switch - Rear blower motor front control feed circuit open - A/C - heater control module Recirc Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3042 Test 1 - 2 Test 3 SYMPTOM RECIRC STATUS INDICATOR FLASHING - MTC TEST NOTE This symptom is diagnosed using the test A/C STATUS INDICATOR FLASHING - MTC. POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Any PCI Bus Indicator Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3043 Test 1 - 4 SYMPTOM ANY PCI BUS INDICATOR INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - No response - instrument cluster - No response - ECM / PCM - Indicator inoperative - Instrument cluster Seat Belt Indicator Always On Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3044 Test 1 SYMPTOM SEAT BELT INDICATOR ALWAYS ON POSSIBLE CAUSES - ACM seat belt indicator command present - Instrument cluster Overhead Console Test 1 - 4 SYMPTOM REPAIRING CMTC DISPLAYS DOUBLE DASH (- - ) IN TEMP DISPLAY POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3045 - No response - PCI BUS - powertrain control module - CMTC BUS message failure - Compass mini-trip computer - Ambient temperature sensor - PCM ambient air temperature sensor DTC present - CMTC internal Left Cylinder Lock Switch Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3046 Test 4 - 5 SYMPTOM LEFT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - left cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - left cylinder lock switch MUX short to voltage Remote Keyless Entry Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3047 Test 1 - 4 Test 5 - 6 SYMPTOM REMOTE KEYLESS ENTRY INOPERATIVE POSSIBLE CAUSES - DTC present - SKREEM DTC present - Test transmitter with tester - RKE transmitter inoperative - RKE transmitter not programmed - SKREEM module - RKE inoperative - SKREEM module - RKE inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3048 Right Cylinder Lock Switch Inoperative Test 1 - 3 Test 4 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3049 SYMPTOM RIGHT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - right cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - right cylinder lock switch MUX short to voltage Power Doors - Liftgate Test 1 - 4 SYMPTOM POWER LIFTGATE INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Power Doors - Sliding Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3050 Test 1 - 4 SYMPTOM POWER SLIDING DOOR INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Alarm Trips On Its Own Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3051 Test 1 - 4 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - Last VTSS cause - Attempt to trip alarm - Intermittent condition Left Front Door Does Not Trip VTSS Test 1 SYMPTOM LEFT FRONT DOOR DOES NOT TRIP VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3052 POSSIBLE CAUSES - Body control module - Check DRBIII(R) for driver door ajar response Left Sliding Door Does Not Trip VTSS Test 1 SYMPTOM LEFT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Monitor DRBIII(R) for left sliding door ajar status - Body control module Right Front Door Does Not Trip VTSS Test 1 SYMPTOM RIGHT FRONT DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for passenger door ajar response - Body control module Right Sliding Door Does Not Trip VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3053 Test 1 SYMPTOM RIGHT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for right rear door ajar response - Body control module VTSS Will Not Arm Test 1 - 3 SYMPTOM VTSS WILL NOT ARM POSSIBLE CAUSES - Check the VTSS status - Check for BCM DTC's and VTSS arming inhibitors - Check for PCI BUS communication of instrument cluster and SKIM - Body control module Six Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3054 - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation Road Testing ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. WARNING: REASSEMBLE ALL COMPONENTS BEFORE ROAD TESTING A VEHICLE. DO NOT TRY TO READ THE DRBIII(R) SCREEN OR OTHER TEST EQUIPMENT DURING A TEST DRIVE. DO NOT HANG THE DRBIII(R) OR OTHER TEST EQUIPMENT FROM THE REARVIEW MIRROR DURING A TEST DRIVE. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIII(R) OR OTHER TEST EQUIPMENT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Vehicle Preparation For Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Glossary of Terms ABS antilock brake system ACT actuator APS adjustable pedals system ATC automatic temperature control BCM body control module BPS bladder pressure sensor BTS belt tension sensor CAB controller antilock brake CMTC compass/mini-trip computer CPA connector positive assurance DAB driver airbag DCHA diesel cabin heater assist (cabin heater) DLC data link connector DTC diagnostic trouble code DR driver EBL electric back lite (rear window defogger) ECM engine control module EVIC electronic vehicle information center FCM front control module GCC Gulf Coast Countries HE hall effect HFM hands free module HVAC heater ventilation, air conditioning IPM integrated power module KNB knee blocker airbag LDU lower drive unit LHD left hand drive MIC mechanical instrument cluster MTC manual temperature control MSMAPM memory seat/mirror/adjustable pedals module NAV navigation NGC next generation controller OBD on board diagnostics OCM occupant classification module OCS occupant classification system OCSVR occupant classification system verification required ODO odometer ORC occupant restraint controller PAB passenger airbag PASS passenger PCI Programmable Communication Interface (vehicle communication bus) PCM powertrain control module PDC power distribution center PLG power liftgate PLGM power liftgate module PSD power sliding door PSDM power sliding door module PWM pulse width modulated RHD Right Hand Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3055 RKE remote keyless entry RX receive SAB seat airbag SBS seat belt switch SBT seat belt tensioner SKREEM sentry key remote entry module SQUIB also called initiator (located inside airbag) SRS supplemental restraint system TCM transmission control module TPMS tire pressure monitor system TX transmit VFD vacuum fluorescent display VTSS vehicle theft security system DRB III Error Messages and Blank Screen DRBIII(R) ERROR MESSAGES Under normal operation, the DRBIII(R) will display one of only two error messages: user-requested WARM Boot or User-Requested COLD Boot. If the DRBIII(R) should display any other error message, record the entire display and call the STAR Center. This is a sample of such an error message display: ver:2.14 date: 26 Jul93 file: key_iff.cc date: Jul26 1993 line: 548 err: 0xi User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRBIII(R) DOES NOT POWER UP (BLANK SCREEN) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRBIII(R). Check for proper grounds at DLC cavities 4 and 5. If all connections are proper between the DRBIII(R) and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRBIII(R) may be the result or a faulty cable or vehicle wiring. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. DRB III Safety Information WARNING: EXCEEDING THE LIMITS OF THE DRBIII(R) MULTIMETER IS DANGEROUS. READ ALL DRBIII(R) INSTRUCTIONS BEFORE USING THE MULTIMETER. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3056 - Follow the vehicle manufacturer s service specifications at all times. - Do not use the DRBIII(R) if it has been damaged. - Do not use the test leads if the insulation is damaged or if metal is exposed. - To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. - Choose the proper range and functions for the measurement. Do not try voltage or current measurement that may exceed the rated capacity. - Do not exceed the limits shown in the table below: *Ohms cannot be measured if voltage is present. Ohms can be measured only in a non-powered circuit. - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10 A. - When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. - When measuring current, connect the meter in series with the load. - Disconnect the live test lead before disconnecting the common test lead. - When using the meter function, keep the DRBIII(R) away from spark plug or coil wires to avoid measuring error from outside interference. KDB Lab Scope Pattern Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3057 PCI Bus Lab Scope Pattern Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 3058 Body Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lower instrument panel silencer. 3. Remove the knee blocker and reinforcement. 4. Disconnect the five wire connectors from the bottom of the Body Control Module (BCM). 5. Move bulkhead wiring aside. 6. Remove the screws holding the BCM to the bulkhead. 7. Remove the BCM from the mounting bracket. INSTALLATION 1. Install the BCM to the mounting bracket. 2. Install the screws holding the BCM to the bulkhead. 3. Connect the five wire connectors to the bottom of the Body Control Module (BCM). 4. Install the knee blocker and reinforcement. 5. Install the lower instrument panel silencer. 6. Connect the battery negative cable. 7. Verify proper operation of BCM and its functions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 3059 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRBIII(R) (diagnostic read-out box) Jumper wires Ohmmeter Voltmeter Sentry Key Tester Test Light 8443 SRS Airbag System Load Tool 9077 Occupant Classification Seat Weights Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs Engine Control Module: Technical Service Bulletins Engine Controls - Programming Generic PCMs NUMBER: 18-029-07 GROUP: Vehicle Performance DATE: April 26, 2007 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-006-04 REV. B, DATED SEPTEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A MINOR REVISION AND **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT UPDATED PL PARTS APPLICATIONS. SUBJECT: Generic Powertrain Control Module (PCM) Procedure OVERVIEW: This bulletin involves programming a generic PCM with software. MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR) Ram Truck 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004-2005 (KJ) Liberty 2004 - 2005 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2004-2005 (PL) Neon 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2005 (TJ) Wrangler Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3064 NOTE: Refer to the table for specific applications. DISCUSSION: Mopar(R) is currently phasing out pre-programmed PCMs for the vehicles listed. New modules will no longer be pre-programmed when received from Mopar(R). Replacement of future PCMs will require programming utilizing the DRBIII(R) and TechCONNECT. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3065 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3066 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3067 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3068 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3069 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: When flashing a 2002 - 2004 LH vehicle the BCM may need to be disconnected if experiencing failures during the flash of the transmission portion of the PCM. The BCM will need to be disconnected after the module ID portion of the flash is complete. Before pressing Page Forward to begin the flash of the PCM Turn the Key to the OFF position and disconnect the BCM. Then turn the KEY to the RUN position and Press Page Forward to begin the PCM flash session. NOTE: If vehicle is a DAKOTA, then the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for any erroneous DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRB III(R) reboots to the MAIN MENU, proceed to Step 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3070 NOTE: If your vehicle is a 2002 LH and the original PCM part number begins with 04 the technician should use the 2002 LH Part Number Reference chart above to determine the corresponding "NEW" part number. This new number from the chart should then be entered into the Tech tools application as the original part number. If the original PCM number begins with 05 no change to the flash selection process is required. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the first ten (10) characters of the "PCM part # " on the repair order for later reference. NOTE: If the PCM is not operational, the part number can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step. 3. Page back to the "Main Menu" 4. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. 5. If the vehicle is not equipped with SKIM then proceed to step 6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with step 6. This information is available from one of the following: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. CAUTION: Failure to install the SKIM pin number into the module after flashing the PCM will cause a start and stall condition. 6. Replace the PCM using the appropriate generic control module. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E, Electronic Control Modules, Powertrain Control Module, Removal/Installation. 7. Open the hood, install a battery charger and verify battery state is above 11.5 volts. 8. If the old "PCM part # " is known, proceed to step 14. If the old "PCM part # " is not known, proceed to next step. 9. On DealerCONNECT select the "Service" tab. 10. Select "Vehicle Information Plus". 11. Manually enter the VIN and mileage and select "Enter". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3071 12. Select the "Vehicle Option" tab. 13. Under the "Vehicle Option window, identify and record: a. Engine. b. Emissions (Federal or California). c. Transmission (Automatic, 5-speed manual, etc.). 14. Connect the DRBIII(R) to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 15. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates. NOTE: Do NOT enter the generic controller part number in step 16a below. 16. Determine the proper calibration: a. If the old "PCM part # " is known, enter the part number of the old controller in the "Parts Criteria p/n window. Proceed to step 16. b. If the old "PCM part # " is not known, select the correct calibration based on the information that was recorded from "Vehicle Options" in step 13. 17. Select the correct calibration. 18. Select the "Download/Update button. 19. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII(R). When the flash process is completed, proceed to next step. 20. Enter the VIN in the PCM. Using the DRBIII® select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "Engine" e. "Miscellaneous" f. "Check VIN" g. If the vehicle is not equipped with SKIM proceed to step 20h. If the vehicle is equipped with SKIM follow the directions on the DRBIII(R). When the VIN and SKIM key has been programmed, proceed to step 20. h. Enter the VIN as requested by the DRBIII(R). 21. Update the PCM mileage. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Check PCM Odometer" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3072 g. "NO" h. Enter the current odometer mileage and then press "Enter". i. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter". 22. Proceed as follows: a. If the vehicle is equipped with an automatic transmission, proceed to step 24. b. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 24. c. If the vehicle is equipped with a Turbo engine and manual transmission, proceed to step 23. 23. On vehicles equipped with a Turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII® Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Pinion Factor" g. Select the correct tire size and then select "Page Back" to exit. h. Proceed to step 24. 24. On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Transmission" e. "Transmission Module" f. "Miscellaneous" g. "Pinion Factor" h. Select the correct tire size and then select "Page Back" to exit. i. Enter "Quick Learn" and then follow the instructions on the DRBIII(R). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3073 25. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3074 Engine Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3075 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3076 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3077 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3078 Engine Control Module: Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views Powertrain Control Module C1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 3081 Powertrain Control Module C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 3082 Powertrain Control Module C3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 3083 Powertrain Control Module C4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 3084 Engine Control Module: Description and Operation Powertrain Control Module (PCM) The Powertrain Control Module (PCM) is a digital computer containing a microprocessor. The PCM receives input signals from various switches and sensors referred to as Powertrain Control Module Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices referred to as Powertrain Control Module Outputs. NOTE: PCM Inputs: - Air Conditioning Pressure Transducer - Ambient temperature Sensor - ASD Relay - Battery Temperature Sensor (NGC) - Battery Voltage - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Distance Sensor (from transmission control module) - EGR Position Feedback - Engine Coolant Temperature Sensor - Heated Oxygen Sensors - Ignition sense - Intake Air Temperature Sensor - Knock Sensor - Leak Detection Pump Feedback - Manifold Absolute Pressure (MAP) Sensor - Park/Neutral - PCI Bus - Power Steering Pressure Switch - Proportional Purge Sense - SCI Receive - Speed Control - Throttle Position Sensor - Transmission Control Relay (Switched B+) - Transmission Pressure Switches - Transmission Temperature Sensor - Transmission Input Shaft Speed Sensor - Transmission Output Shaft Speed Sensor - Transaxle Gear Engagement Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 3085 - Vehicle Speed NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Automatic Shut Down (ASD) and Fuel Pump Relays - Data Link Connector (PCI and SCI Transmit) - Double Start Override - EGR Solenoid - Fuel Injectors - Generator Field - High Speed Fan Relay - Idle Air Control Motor - Ignition Coils - Leak Detection Pump - Low Speed Fan Relay - MTV Actuator - Proportional Purge Solenoid - SRV Valve - Speed Control Relay - Speed Control Vent Relay - Speed Control Vacuum Relay - 8 Volt Output - 5 Volt Output - Torque Reduction Request - Transmission Control Relay - Transmission Solenoids - Vehicle Speed Based on inputs it receives, the powertrain control module (PCM) adjusts fuel injector pulse width, idle speed, ignition timing, and canister purge operation. The PCM regulates the cooling fans, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the generator field. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. - Battery Voltage - Intake Air Temperature Sensor - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Exhaust Gas Oxygen Content (heated oxygen sensors) - Manifold Absolute Pressure - Throttle Position The PCM adjusts engine idle speed through the idle air control motor based on the following inputs. - Brake Switch - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Park/Neutral - Transaxle Gear Engagement - Throttle Position - Vehicle Speed The PCM adjusts ignition timing based on the following inputs. - Intake Air Temperature - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Knock Sensor - Manifold Absolute Pressure - Park/Neutral - Transaxle Gear Engagement - Throttle Position The automatic shut down (ASD) and fuel pump relays are mounted externally, but turned on and off by the powertrain control module through the same circuit. The camshaft and crankshaft signals are sent to the powertrain control module. If the PCM does not receive both signals within approximately one second of engine cranking, it deactivates the ASD and fuel pump relays. When these relays are deactivated, power is shut off to the fuel injectors, ignition coils, fuel pump and the heating element in each oxygen sensor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 3086 The PCM contains a voltage converter that changes battery voltage to a regulated 8.0 volts. The 8.0 volts power the camshaft position sensor, crankshaft position sensor and vehicle speed sensor. The PCM also provides a 5.0 volts supply for the engine coolant temperature sensor, intake air temperature sensor, manifold absolute pressure sensor and throttle position sensor. The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage in new PCM. Use the DRBIII(R) scan tool to change the mileage in the PCM. TRANSMISSION CONTROL CLUTCH VOLUME INDEX (CVI) Example Of CVI Calculation An important function of the PCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The PCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the PCM that represents input shaft rpm. The Output Speed Sensor provides the PCM with output shaft speed information. By comparing the two inputs, the PCM can determine transaxle gear ratio. This is important to the CVI calculation because the PCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the PCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the PCM can determine the volume of fluid used to apply or release a friction element. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 3087 The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: SHIFT SCHEDULES As mentioned earlier, the PCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Part 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 3088 Part 2 As driving conditions change, the PCM appropriately adjusts the shift schedule. Refer to the chart to determine the appropriate operation expected, depending on driving conditions. SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). DATA BUS COMMUNICATION RECEIVE - PCM INPUT The PCM uses the SCI communication bus to preform engine diagnostics and flash operations. The transmission side of the PCM uses the SCI communication bus to flash new software. However, diagnostics is performed via the vehicles J1850 bus for the transmission side of the PCM. IGNITION SENSE - PCM INPUT The ignition sense input informs the Powertrain Control Module (PCM) that the ignition switch is in the crank or run position. PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded separately from the ground pins. 5 VOLT SUPPLY - PCM OUTPUT The PCM supplies 5 volts to the following sensors: - A/C pressure transducer - Ambient Temperature sensor - Battery temperature - Camshaft Position Sensor (NGC) - Crankshaft Position Sensor (NGC) - Engine coolant temperature sensor - Inlet Air Temperature Sensor - Knock sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 3089 - Linear EGR solenoid (if equipped) - Manifold absolute pressure sensor - Oil Pressure Switch - Throttle position sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming Engine Control Module: Service and Repair PCM/SKIM Programming NOTE: Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. When a PCM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new PCM. 2. Program the new SKIM. 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE PCM The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the scan tool. Perform the following steps to program the secret key into the PCM. 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Enter secured access mode by entering the vehicle four-digit PIN. 5. Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 6. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). 7. Press Page Back to get to the Select System menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK. 8. The scan tool will ask, Is odometer reading between XX and XX? Select the YES or NO button on the scan tool. If NO is selected, the scan tool will read, Enter odometer Reading. Enter the odometer reading from the Instrument Panel and press ENTER. PROGRAMMING THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Program the vehicle four-digit PIN into SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. 6. Select YES to update VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the secret key (the PCM will send the secret key to the SKIM). 8. Program ignition keys to SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEY'S. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following messages: Programming Not Attempted The scan tool attempts to read the programmed key status and there are no keys programmed into SKIM memory. Programming Key Failed (Possible Used Key From Wrong Vehicle) SKIM is unable to program key due to one of the following: - faulty ignition key transponder - ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming > Page 3092 - SKIM transponder ID memory is full. 5. Obtain ignition keys to be programmed from customer (8 keys maximum). 6. Using the scan tool, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN. KEYS. 7. Program all ignition keys. Learned Key In Ignition Ignition key transponder ID is currently programmed in SKIM memory. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming > Page 3093 Engine Control Module: Service and Repair Powertrain Control Module SBEC Controller REMOVAL 1. Disconnect the negative battery cable. 2. Remove the battery shield. PCM 3. Remove the 2 upper PCM bracket bolts. 4. Remove the 2 PCM connectors. 5. Remove the headlamp PCM Lower Bolt 6. Remove the lower PCM mounting bolt. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming > Page 3094 7. Remove PCM. INSTALLATION 1. Install the PCM. 2. Install the lower PCM mounting bolt. Tighten bolt. 3. Install the 2 upper PCM bracket bolts. Tighten bolt. 4. Install the headlamp. 5. Install the 2 PCM connectors. 6. Install the battery shield. 7. Connect the negative battery cable. NGC Controller REMOVAL NGC Controller Location The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage and vehicle identification number (VIN) in the new PCM. Use the DRBIII(R) scan tool to change the millage and VIN in the PCM. If this step is not done a Diagnostic Trouble Code (DTC) may be set. 1. Turn wheels to the left. 2. Disconnect the negative battery cable. 3. Raise vehicle and support. Splash Shield Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming > Page 3095 4. Remove the left front wheel well splash shield. NGC Controller 5. Unlock and disconnect the electrical connectors. 6. Remove 3 screws from PCM to mounting bracket. 7. Remove the PCM. INSTALLATION The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage and vehicle identification number (VIN) in the new PCM. Use the DRBIII(R) scan tool to change the millage and VIN in the PCM. If this step is not done a diagnostic trouble code (DTC) may be set and SKIM must be done or car will not start if it is a SKIM equipped car. If a SKIM car you must do a secret key transfer also. 1. Install PCM module to the mounting bracket. 2. Install electrical connectors and lock. 3. Install the splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. 6. Using DRBIII(R) scan tool, program mileage and vehicle identification number (VIN) into PCM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3099 Main Relay (Computer/Fuel System): Diagrams Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3100 Auto Shut Down Relay Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3101 Main Relay (Computer/Fuel System): Description and Operation AUTO SHUT DOWN RELAY The relay is located in the Power Distribution Center (PDC). For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary The engine switched battery (NGC vehicles) informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is also used to power certain drivers on NGC vehicles. When energized, the ASD relay on NGC vehicles provides power to operate the injectors, ignition coil, generator field, O2 sensor heaters (both upstream and downstream), evaporative purge solenoid, EGR solenoid (if equipped) wastegate solenoid (if equipped), and NVLD solenoid (if equipped). The ASD relay also provides a sense circuit to the PCM for diagnostic purposes. If the PCM does not receive 12 volts from this input after grounding the control side of the ASD relay, it sets a Diagnostic Trouble Code (DTC). The PCM energizes the ASD any time there is an engine speed that exceeds a predetermined value (typically about 50 rpm). The ASD relay can also be energized after the engine has been turned off to perform an O2 sensor heater test, if vehicle is equipped with OBD II diagnostics. As mentioned earlier, the PCM energizes the ASD relay during an O2 sensor heater test. On NGC vehicles it checks the O2 heater upon vehicle start. The PCM still operates internally to perform several checks, including monitoring the O2 sensor heaters. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3106 Fuel Pump Relay: Description and Operation The fuel pump relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. The fuel pump relay supplies battery voltage to the fuel pump. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuel pump relay power circuit contains a fuse between the buss bar in the PDC and the relay. The fuse is located in the PDC. Refer to the Wiring Diagrams for circuit information. The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position. When the ignition switch is in the On position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3110 Main Relay (Computer/Fuel System): Diagrams Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3111 Auto Shut Down Relay Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3112 Main Relay (Computer/Fuel System): Description and Operation AUTO SHUT DOWN RELAY The relay is located in the Power Distribution Center (PDC). For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary The engine switched battery (NGC vehicles) informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is also used to power certain drivers on NGC vehicles. When energized, the ASD relay on NGC vehicles provides power to operate the injectors, ignition coil, generator field, O2 sensor heaters (both upstream and downstream), evaporative purge solenoid, EGR solenoid (if equipped) wastegate solenoid (if equipped), and NVLD solenoid (if equipped). The ASD relay also provides a sense circuit to the PCM for diagnostic purposes. If the PCM does not receive 12 volts from this input after grounding the control side of the ASD relay, it sets a Diagnostic Trouble Code (DTC). The PCM energizes the ASD any time there is an engine speed that exceeds a predetermined value (typically about 50 rpm). The ASD relay can also be energized after the engine has been turned off to perform an O2 sensor heater test, if vehicle is equipped with OBD II diagnostics. As mentioned earlier, the PCM energizes the ASD relay during an O2 sensor heater test. On NGC vehicles it checks the O2 heater upon vehicle start. The PCM still operates internally to perform several checks, including monitoring the O2 sensor heaters. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Shut Down Relay (For Antitheft) > Component Information > Description and Operation Ignition Shut Down Relay (For Antitheft): Description and Operation AUTO SHUT DOWN RELAY The relay is located in the Power Distribution Center (PDC). For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary The engine switched battery (NGC vehicles) informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is also used to power certain drivers on NGC vehicles. When energized, the ASD relay on NGC vehicles provides power to operate the injectors, ignition coil, generator field, O2 sensor heaters (both upstream and downstream), evaporative purge solenoid, EGR solenoid (if equipped) wastegate solenoid (if equipped), and NVLD solenoid (if equipped). The ASD relay also provides a sense circuit to the PCM for diagnostic purposes. If the PCM does not receive 12 volts from this input after grounding the control side of the ASD relay, it sets a Diagnostic Trouble Code (DTC). The PCM energizes the ASD any time there is an engine speed that exceeds a predetermined value (typically about 50 rpm). The ASD relay can also be energized after the engine has been turned off to perform an O2 sensor heater test, if vehicle is equipped with OBD II diagnostics. As mentioned earlier, the PCM energizes the ASD relay during an O2 sensor heater test. On NGC vehicles it checks the O2 heater upon vehicle start. The PCM still operates internally to perform several checks, including monitoring the O2 sensor heaters. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Specifications Specifications - Battery Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Specifications > Page 3122 Battery Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Specifications > Page 3123 Battery Temperature Sensor: Description and Operation (NGC Vehicles) The PCM incorporates a Battery Temperature Sensor (BTS) on its circuit board. The PCM uses the temperature of the battery area to control the charge system voltage. This temperature, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as temperature around the battery increases. For vehicles with 1.6L engine, there is no physical battery temp sensor in place to detect battery temp. Rather, an algorithm built in PCM is employed to predict battery temp using inlet air temp, vehicle speed, and coolant temp, among other signals. The PCM maintains the optimal output of the generator by monitoring battery voltage and controlling it to a range of 13.5 - 14.7 volts based on battery temperature. The system target voltage is 13.5 - 14.7 volts. However the actual voltage go below this during heavy electrical loads and generator speeds. Also the actual voltage can be lower than the target voltage between the battery and the battery voltage sense circuit, approximately 0.2 - 0.3 volts. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20°F. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Specifications > Page 3124 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor is not serviced separately. If replacement is necessary, the PCM must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 3129 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3130 Camshaft Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3131 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor EGR/CAM Sensor 2.4L The camshaft position sensor for the 3.3/3.8L is mounted in the front of the timing case cover and the camshaft position sensor for the 2.4L is mounted on the end of the cylinder head. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3132 Camshaft Position Sensor The camshaft position sensor provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it (Fig. 2). The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. Camshaft Position Sensor When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3133 Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the sensor. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs on represent which cylinder the flat spot and notches identify, they do not indicate TDC position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3134 NGC Typical Scope Patterns Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3135 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. Air Box Cover 2. Remove the air box cover and inlet tube. Camshaft Position Sensor 3. Disconnect camshaft position sensor electrical connector from the wiring harness connector. 4. Remove bolt holding sensor. 5. Rotate sensor away from block. 6. Pull sensor up out of the chain case cover. Do not pull on the sensor wiring. There is an O-ring on the body of the sensor. The O-ring may make removal difficult. A light tap to top of sensor prior to removal may reduce force needed for removal. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3136 Camshaft Position Sensor And Spacer If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. While holding the sensor in this position, install and tighten the retaining bolt 14 N.m (125 in. lbs.) torque. 4. Connect camshaft position sensor electrical connector to harness connector. 5. Install the air box cover and inlet hose. 6. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations 3.3L & 3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 3144 Crankshaft Position Sensor: Connector Locations Starter Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 3145 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3146 Crankshaft Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3147 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR Crankshaft Sensor 2.4L The 2.4L crankshaft sensor is located on the rear of the engine near the accessory drive belt. The 3.3L/3.8L crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3148 Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3149 NGC Typical Scope Patterns Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Pump Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3153 Fuel Level Sensor: Service and Repair Fuel Pump/Level Sensor Electrical Connector Wire Terminal Locking Finger Removing Wires From Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3154 Loosening Level Sensor Level Sensor Removal/Installation Groove In Back Side Of Level Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3155 Installation Channel Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3160 Intake Air Temperature Sensor: Connector Locations Inlet Air Sensors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3161 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3162 Inlet Air Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3163 Intake Air Temperature Sensor: Description and Operation 3.3/3.8L IAT Sensor The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation The knock sensor threads into the cylinder block. The knock sensor is designed to detect engine vibration that is caused by detonation. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives as an input the knock sensor voltage signal. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except WOT. The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3170 Manifold Absolute Pressure Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3171 Manifold Pressure/Vacuum Sensor: Description and Operation Map Sensor 2.4L Map Sensor 3.3/3.8L The MAP sensor mounts to the intake manifold The sensor is connects electrically to the PCM The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a volt-age signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5 V and full scale is 4.5 V. For a pressure swing of 0 - 15 psi the voltage changes 4.O V. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key on. The difference between current and what it was at key on is manifold vacuum. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3172 During key On (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in you work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key On the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC 1 transmissions only via the PCI bus) - Idle speed - Decel fuel shutoff The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 29.92 in Hg. For every 100 feet of altitude barometric pressure drops .10 in. Hg. If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3173 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. Map Sensor 3.3/3.8L 2. Remove vacuum hose and mounting screws from manifold absolute pressure (MAP) sensor. 3. Disconnect electrical connector from sensor. Remove sensor. INSTALLATION 1. Install sensor. 2. Install screws and tighten to PLASTIC MANIFOLD 1.7 N.m (15 in. lbs.) ALUMINUM MANIFOLD 3.3 N.m (30 in. lbs.). 3. Connect the electrical connector to the sensor. Install vacuum hose. 4. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Oxygen Sensors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 3177 3.3-3.8 Liter Engine Front Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 3178 Engine Pressure Switch (GAS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC P0135 Set NUMBER: 18-010-05 REV. A GROUP: Vehicle Performance DATE: March 4, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-010-05, DATED FEBRUARY 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN UPDATED VEHICLE BUILD DATE. THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD APRIL, 2005. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DIG) P0135 - 02 Sensor 1/1 Heater Performance OVERVIEW: This bulletin involves verifying the proper 1/1 02 Sensor is installed on the vehicle and reprogramming the Powertrain Control Module with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager NOTE: **This bulletin applies to 2005 CS and RS vehicles equipped with a 3.8L engine (sales code EGH) built on and between July 8, 2004 (MDH 0708XX) and March 2, 2005 (MDH 0302XX). 2005 RS vehicles equipped with a 3.3L engine (sales code EGA, EGM and EGH) built on and between July 8, 2004 (MDH 0708XX) and October 29, 2004 (MDH 1029XX).** SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by the following Diagnostic Trouble Codes (DTC's): P0135 - 02 Sensor 1/1 Heater Performance DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than the one listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. Verify that the correct 02 Sensor is installed on the vehicle. Refer to Service Bulletin 08-008-05. Installing an incorrect 1/1 02 sensor will cause a MIL illumination for DTC P0135 - 02 Sensor 1/1 Heater Performance to be set. If the vehicle operator describes or experiences the Symptom/Condition and the correct 1/1 02 sensor is installed on the vehicle, perform the Repair Procedure. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 3187 SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 3188 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 08-008-05 > Feb > 05 > Engine Controls - MIL ON/DTC P0135 (O2 Sensor) Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC P0135 (O2 Sensor) NUMBER: 08-008-05 GROUP: Electrical DATE: February 4, 2005 SUBJECT: 1/1 02 Sensor Usage MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager 2005 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to 2005 CS vehicles equipped with a 3.8L engine (sales code EGH), 2005 RS or 2005 RG vehicles equipped with a 3.313.8L engine (sales code EGA, EGM and EGH). DISCUSSION: A new 1/1 02 sensor (PN 56029085AA) has been introduced on the 3.313.8L engines for the 2005 RS/RG and CS vehicles built after July 8, 2004 (MDH 0708XX). Installing an incorrect 1/1 02 sensor will cause a MIL illumination for DTC P0135 - 02 Sensor 1/1 Heater Performance to be set. The operation of the new 02 sensor has also changed. The new 1/1 02 sensor runs at 100% duty cycle all the time because the resistance of the heater is higher. Monitoring the 1/1 02 sensor with the DRBIII(R) while the vehicle is in the service bay will show 100% duty cycle, which is normal for this new sensor. 2005 Model Year 1/1 02 Sensor Usage POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0135 Set NUMBER: 18-010-05 REV. A GROUP: Vehicle Performance DATE: March 4, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-010-05, DATED FEBRUARY 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN UPDATED VEHICLE BUILD DATE. THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD APRIL, 2005. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DIG) P0135 - 02 Sensor 1/1 Heater Performance OVERVIEW: This bulletin involves verifying the proper 1/1 02 Sensor is installed on the vehicle and reprogramming the Powertrain Control Module with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager NOTE: **This bulletin applies to 2005 CS and RS vehicles equipped with a 3.8L engine (sales code EGH) built on and between July 8, 2004 (MDH 0708XX) and March 2, 2005 (MDH 0302XX). 2005 RS vehicles equipped with a 3.3L engine (sales code EGA, EGM and EGH) built on and between July 8, 2004 (MDH 0708XX) and October 29, 2004 (MDH 1029XX).** SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by the following Diagnostic Trouble Codes (DTC's): P0135 - 02 Sensor 1/1 Heater Performance DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than the one listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. Verify that the correct 02 Sensor is installed on the vehicle. Refer to Service Bulletin 08-008-05. Installing an incorrect 1/1 02 sensor will cause a MIL illumination for DTC P0135 - 02 Sensor 1/1 Heater Performance to be set. If the vehicle operator describes or experiences the Symptom/Condition and the correct 1/1 02 sensor is installed on the vehicle, perform the Repair Procedure. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 3198 SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 3199 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 08-008-05 > Feb > 05 > Engine Controls - MIL ON/DTC P0135 (O2 Sensor) Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0135 (O2 Sensor) NUMBER: 08-008-05 GROUP: Electrical DATE: February 4, 2005 SUBJECT: 1/1 02 Sensor Usage MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager 2005 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to 2005 CS vehicles equipped with a 3.8L engine (sales code EGH), 2005 RS or 2005 RG vehicles equipped with a 3.313.8L engine (sales code EGA, EGM and EGH). DISCUSSION: A new 1/1 02 sensor (PN 56029085AA) has been introduced on the 3.313.8L engines for the 2005 RS/RG and CS vehicles built after July 8, 2004 (MDH 0708XX). Installing an incorrect 1/1 02 sensor will cause a MIL illumination for DTC P0135 - 02 Sensor 1/1 Heater Performance to be set. The operation of the new 02 sensor has also changed. The new 1/1 02 sensor runs at 100% duty cycle all the time because the resistance of the heater is higher. Monitoring the 1/1 02 sensor with the DRBIII(R) while the vehicle is in the service bay will show 100% duty cycle, which is normal for this new sensor. 2005 Model Year 1/1 02 Sensor Usage POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3206 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3207 Oxygen Sensor: Connector Locations Oxygen Sensors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3208 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3209 3.3-3.8 Liter Engine Front Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3210 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream (3.3L/3.8L) Oxygen Sensor 1/2 Downstream (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3211 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3212 Oxygen Sensor: Description and Operation O2 Sensor Upstream 1/1 - 2.4L O2 Sensor Upstream 1/1 - 3.3/3.8L The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3213 O2 Sensor Downstream 1/2 - 2.4/3.3/3.8L The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic convertor. A separate upstream and downstream grounds are used on the NGC vehicles (4 Cyl). As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor, one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The 02 sensors produce a constant 2.5 volts on NGC vehicles, depending upon the oxygen content of the exhaust gas. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produces a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2 sensors input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. NGC Controller - Has a common ground for the heater in the 02S. 12 volts is supplied to the heater in the 02S by the NGC controller. Both the upstream and downstream 02 sensors for NGC are pulse width modulation (PWM). NOTE: When replacing an 02 Sensor, the PCM RAM memory must be cleared, either by disconnecting the PCM C-1 connector or momentarily disconnecting the Battery negative terminal. The NGC learns the characteristics of each O2 heater element and these old values should be cleared when installing a new 02 sensor. The customer may experience driveability issues if this is not performed. UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 2.5 to 3.5 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 2.5 volt. When there is a lesser amount of oxygen present (rich air/fuel mixture) the sensor produces a voltage as high as 3.5 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3214 The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. DOWNSTREAM OXYGEN SENSOR The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. Also used to establish the upstream 02 goal voltage (switching point). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor REMOVAL - DOWNSTREAM 1/2 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Downstream Oxygen Sensor (1/2) 3. Disconnect the electrical connector. Downstream 2/1 O2 Sensor 4. Use a socket such as the Snap-On(R) YA8875 or equivalent to remove the sensor. 5. When the sensor is removed, the threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using the original sensor, coat the threads with Loctite 771 - 64 anti-seize compound or equivalent. INSTALLATION - DOWNSTREAM 2/1 The O2S is located on the side of the catalytic converter. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 3217 Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install sensor and tighten to 27 N.m (20 ft. lbs.). 2. Connect the electrical connector. 3. Lower vehicle. 4. Install the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 3218 Oxygen Sensor: Service and Repair Upstream Sensor REMOVAL - UPSTREAM 1/1 1. Remove battery, refer to the Battery section for more information. 2. Remove the battery tray, refer to the Battery section for more information. 3. Disconnect the speed control vacuum harness from servo. 4. Disconnect the electrical connector from servo. 5. Remove the speed control servo and bracket and reposition. O2 Sensor 1/1 6. Use a socket such as the Snap-On(R) YA8875 or equivalent to remove the sensor. 7. When the sensor is removed, the threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using the original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. INSTALLATION - UPSTREAM 1/1 The engines uses two heated oxygen sensors. 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771 - 64 or equivalent. New sensors have compound on the threads and do not require an additional coating. 2. Install sensor and tighten to 27 N.m (20 ft. lbs.). 3. Connect the electrical connector for the O2 sensor and install onto bracket. 4. Connect the electrical connector for the speed control servo. 5. Install the speed control servo and bracket refer to the Speed Control Servo for more information. 6. Connect the speed control vacuum harness to servo. 7. Install the battery tray, refer to the Battery section for more information. 8. Install battery, refer to the Battery section for more information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 3219 Oxygen Sensor: Tools and Equipment O2S (Oxygen Sensor) Removal/Install - C 4907 O2S (Oxygen Sensor) Removal/Install - 8439 O2S (Oxygen Sensor) Removal/Installation C 4907 O2S (Oxygen Sensor) Removal/Installer - 8439 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 3224 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3225 Throttle Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3226 Throttle Position Sensor: Description and Operation Throttle Position Sensor 2.4L Engine Throttle Position Sensor 3.3/3.8L Engine The throttle position sensor mounts to the side of the throttle body.The sensor connects to the throttle blade shaft. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3227 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the electrical connector from the Inlet Air Temperature sensor. 3. Remove the air cleaner box lid. Remove hose from throttle body. 4. Disconnect the electrical connector at TPS. 5. Disconnect the electrical connector at IAC. 6. Remove the throttle and speed control cables from throttle body. 7. Remove 3 mounting bolts from throttle body. 8. Remove throttle body. 9. Disconnect the purge vacuum line from the throttle body. 10. Remove TPS from throttle body. INSTALLATION 1. Install TPS to throttle body. 2. Disconnect the purge vacuum line from the throttle body. 3. Install throttle body. 4. Install 3 mounting bolts from throttle body. Tighten bolts. 5. Install the throttle and speed control cables to throttle body. 6. Connect the electrical connector at TPS. 7. Connect the electrical connector at IAC. 8. Install the air cleaner box lid. Install hose to throttle body. 9. Install the electrical connector to the Inlet Air Temperature sensor. 10. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR Sensor, Transmission Range Sensor ...................................................................................................................................................... 5 Nm (45 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 3233 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3234 Transmission Range Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 337). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 338). OPERATION The Transmission Range Sensor (TRS) (Fig. 337) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 3237 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 338) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 3238 Transmission Position Switch/Sensor: Description and Operation 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 303). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM/TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 304). OPERATION The Transmission Range Sensor (TRS) (Fig. 303) communicates Shift Lever Position (SLP) to the PCM/TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the PCM/TCM receives from four sense circuits. The PCM/TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the PCM/TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 3239 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 304) that the PCM/TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the PCM/TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the PCM/TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 3240 Transmission Position Switch/Sensor: Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle Transmission Position Switch/Sensor: Service and Repair 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 305). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 305) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 3243 Transmission Position Switch/Sensor: Service and Repair 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 339). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 339) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 3244 Transmission Position Switch/Sensor: Service and Repair 41TE REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 343). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 343) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation Vehicle Speed Sensor: Description and Operation Vehicle Speed and Distance Description The PCM receives a signal from the transaxle output speed sensor over the bus communication line. Operation The 4 speed automatic transaxle output speed sensor supplies the speed input to the PCM. The PCM determines acceleration rates. The speed control software in the PCM uses vehicle speed and acceleration to control to the set speed. For more information of the Output Speed Sensor please refer to: See: Transmission Control Systems/Sensors and Switches - Transmission and Drivetrain/Sensors and Switches A/T/Transmission Speed Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 3253 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3254 Throttle Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3255 Throttle Position Sensor: Description and Operation Throttle Position Sensor 2.4L Engine Throttle Position Sensor 3.3/3.8L Engine The throttle position sensor mounts to the side of the throttle body.The sensor connects to the throttle blade shaft. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3256 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the electrical connector from the Inlet Air Temperature sensor. 3. Remove the air cleaner box lid. Remove hose from throttle body. 4. Disconnect the electrical connector at TPS. 5. Disconnect the electrical connector at IAC. 6. Remove the throttle and speed control cables from throttle body. 7. Remove 3 mounting bolts from throttle body. 8. Remove throttle body. 9. Disconnect the purge vacuum line from the throttle body. 10. Remove TPS from throttle body. INSTALLATION 1. Install TPS to throttle body. 2. Disconnect the purge vacuum line from the throttle body. 3. Install throttle body. 4. Install 3 mounting bolts from throttle body. Tighten bolts. 5. Install the throttle and speed control cables to throttle body. 6. Connect the electrical connector at TPS. 7. Connect the electrical connector at IAC. 8. Install the air cleaner box lid. Install hose to throttle body. 9. Install the electrical connector to the Inlet Air Temperature sensor. 10. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 3262 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3263 Camshaft Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3264 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor EGR/CAM Sensor 2.4L The camshaft position sensor for the 3.3/3.8L is mounted in the front of the timing case cover and the camshaft position sensor for the 2.4L is mounted on the end of the cylinder head. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3265 Camshaft Position Sensor The camshaft position sensor provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it (Fig. 2). The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. Camshaft Position Sensor When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3266 Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the sensor. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs on represent which cylinder the flat spot and notches identify, they do not indicate TDC position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3267 NGC Typical Scope Patterns Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3268 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. Air Box Cover 2. Remove the air box cover and inlet tube. Camshaft Position Sensor 3. Disconnect camshaft position sensor electrical connector from the wiring harness connector. 4. Remove bolt holding sensor. 5. Rotate sensor away from block. 6. Pull sensor up out of the chain case cover. Do not pull on the sensor wiring. There is an O-ring on the body of the sensor. The O-ring may make removal difficult. A light tap to top of sensor prior to removal may reduce force needed for removal. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3269 Camshaft Position Sensor And Spacer If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. While holding the sensor in this position, install and tighten the retaining bolt 14 N.m (125 in. lbs.) torque. 4. Connect camshaft position sensor electrical connector to harness connector. 5. Install the air box cover and inlet hose. 6. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations 3.3L & 3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 3274 Crankshaft Position Sensor: Connector Locations Starter Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 3275 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3276 Crankshaft Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3277 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR Crankshaft Sensor 2.4L The 2.4L crankshaft sensor is located on the rear of the engine near the accessory drive belt. The 3.3L/3.8L crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3278 Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3279 NGC Typical Scope Patterns Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation KEY/LOCK CYLINDER DESCRIPTION The lock cylinder is inserted in the end of the housing opposite the ignition switch. OPERATION The ignition key rotates the cylinder to 5 different detents (Fig. 30): Accessory - Off (lock) - Unlock - On/Run - Start Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 3284 Ignition Switch Lock Cylinder: Service and Repair Key/Lock Cylinder REMOVAL 1. Disconnect negative cable from battery. 2. Remove steering column cover retaining screws. 3. Remove screws holding steering column shrouds and remove lower shroud. 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab on the bottom of the lock housing and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position (Fig. 31). 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6. Install steering column cover. 7. Connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation The knock sensor threads into the cylinder block. The knock sensor is designed to detect engine vibration that is caused by detonation. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives as an input the knock sensor voltage signal. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except WOT. The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ............................... 400 kPa ± 34 kPa (58 psi ± 5 psi) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check Fuel Pressure: Testing and Inspection Fuel Delivery Check Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 3294 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 3295 Test 7 - 9 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specs - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump module - Fuel delivery system operation - Fuel pump relay fused B+ circuit - (A141) fuel pump relay output circuit open - (Z1) fuel pump ground circuit open/high resistance - Fuel pump module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 3296 Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test Test 1 - 2 SYMPTOM CHECKING FUEL PRESSURE LEAK DOWN POSSIBLE CAUSES - Checking fuel pressure - Fuel pump module - Checking fuel leak down Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications The cylinders are numbered from the front of the engine to the rear. The front cylinder bank is numbered 2, 4, 6. The rear cylinder bank is numbered 1, 3, 5. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > Electrical Specifications > Page 3301 Firing Order: Mechanical Specifications Firing Order 1-2-3-4-5-6 .............................................................................................................................................................. ......................................... Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations The cylinders are numbered from the front of the engine to the rear. The front cylinder bank is numbered 2, 4, 6. The rear cylinder bank is numbered 1, 3, 5. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set Ignition Cable: Customer Interest Engine Controls/Ignition - MIL ON/Misfire DTC's Set NUMBER: 18-018-04 GROUP: Vehicle Performance DATE: April 27, 2004 THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD JUNE, 2004. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303, P0304, P0305, P0306 OVERVIEW: This bulletin involves replacing the spark plugs, ignition wires and if necessary, reprogramming the Powertrain Control Module with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004 (MDH 0402XX). SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC's: ^ P0300-MULTIPLE CYLINDER MISFIRE ^ P0301-CYLINDER # 1 MISFIRE ^ P0302-CYLINDER # 2 MISFIRE ^ P0303-CYLINDER # 3 MISFIRE ^ P0304-CYLINDER # 4 MISFIRE ^ P0305-CYLINDER # 5 MISFIRE ^ P0306-CYLINDER # 6 MISFIRE DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform Repair Procedure 1 and if necessary, Repair Procedure 2. If an "Authorized Modification Label" is present and states that Service Bulletin 18-016-04 has been performed, it is not necessary to perform Repair Procedure 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 3314 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE 1: Replace spark plugs and ignition cables 1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service information available in TechCONNECT or the Town & Country and Caravan service manual (publication no. 81-370-04062CD), page 8I-10. 2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2. If Service Bulletin 18-016-04 has been performed, no further action is necessary. REPAIR PROCEDURE 2: Flash Reprogram PCM NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 3315 c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select 'Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 3316 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set Ignition Cable: All Technical Service Bulletins Engine Controls/Ignition - MIL ON/Misfire DTC's Set NUMBER: 18-018-04 GROUP: Vehicle Performance DATE: April 27, 2004 THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD JUNE, 2004. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303, P0304, P0305, P0306 OVERVIEW: This bulletin involves replacing the spark plugs, ignition wires and if necessary, reprogramming the Powertrain Control Module with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004 (MDH 0402XX). SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC's: ^ P0300-MULTIPLE CYLINDER MISFIRE ^ P0301-CYLINDER # 1 MISFIRE ^ P0302-CYLINDER # 2 MISFIRE ^ P0303-CYLINDER # 3 MISFIRE ^ P0304-CYLINDER # 4 MISFIRE ^ P0305-CYLINDER # 5 MISFIRE ^ P0306-CYLINDER # 6 MISFIRE DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform Repair Procedure 1 and if necessary, Repair Procedure 2. If an "Authorized Modification Label" is present and states that Service Bulletin 18-016-04 has been performed, it is not necessary to perform Repair Procedure 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 3322 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE 1: Replace spark plugs and ignition cables 1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service information available in TechCONNECT or the Town & Country and Caravan service manual (publication no. 81-370-04062CD), page 8I-10. 2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2. If Service Bulletin 18-016-04 has been performed, no further action is necessary. REPAIR PROCEDURE 2: Flash Reprogram PCM NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 3323 c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select 'Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 3324 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Technical Service Bulletins > Page 3325 Ignition Cable: Description and Operation SPARK PLUG CABLE Spark Plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the ignition coil pack to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Check the spark plug cable connections for good contact at the coil, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean Spark Plug cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. The spark plug cables and spark plug boots are made from high temperature materials. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set Spark Plug: Customer Interest Engine Controls/Ignition - MIL ON/Misfire DTC's Set NUMBER: 18-018-04 GROUP: Vehicle Performance DATE: April 27, 2004 THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD JUNE, 2004. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303, P0304, P0305, P0306 OVERVIEW: This bulletin involves replacing the spark plugs, ignition wires and if necessary, reprogramming the Powertrain Control Module with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004 (MDH 0402XX). SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC's: ^ P0300-MULTIPLE CYLINDER MISFIRE ^ P0301-CYLINDER # 1 MISFIRE ^ P0302-CYLINDER # 2 MISFIRE ^ P0303-CYLINDER # 3 MISFIRE ^ P0304-CYLINDER # 4 MISFIRE ^ P0305-CYLINDER # 5 MISFIRE ^ P0306-CYLINDER # 6 MISFIRE DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform Repair Procedure 1 and if necessary, Repair Procedure 2. If an "Authorized Modification Label" is present and states that Service Bulletin 18-016-04 has been performed, it is not necessary to perform Repair Procedure 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 3334 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE 1: Replace spark plugs and ignition cables 1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service information available in TechCONNECT or the Town & Country and Caravan service manual (publication no. 81-370-04062CD), page 8I-10. 2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2. If Service Bulletin 18-016-04 has been performed, no further action is necessary. REPAIR PROCEDURE 2: Flash Reprogram PCM NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 3335 c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select 'Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 3336 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set Spark Plug: All Technical Service Bulletins Engine Controls/Ignition - MIL ON/Misfire DTC's Set NUMBER: 18-018-04 GROUP: Vehicle Performance DATE: April 27, 2004 THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD JUNE, 2004. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303, P0304, P0305, P0306 OVERVIEW: This bulletin involves replacing the spark plugs, ignition wires and if necessary, reprogramming the Powertrain Control Module with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004 (MDH 0402XX). SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC's: ^ P0300-MULTIPLE CYLINDER MISFIRE ^ P0301-CYLINDER # 1 MISFIRE ^ P0302-CYLINDER # 2 MISFIRE ^ P0303-CYLINDER # 3 MISFIRE ^ P0304-CYLINDER # 4 MISFIRE ^ P0305-CYLINDER # 5 MISFIRE ^ P0306-CYLINDER # 6 MISFIRE DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform Repair Procedure 1 and if necessary, Repair Procedure 2. If an "Authorized Modification Label" is present and states that Service Bulletin 18-016-04 has been performed, it is not necessary to perform Repair Procedure 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 3342 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE 1: Replace spark plugs and ignition cables 1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service information available in TechCONNECT or the Town & Country and Caravan service manual (publication no. 81-370-04062CD), page 8I-10. 2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2. If Service Bulletin 18-016-04 has been performed, no further action is necessary. REPAIR PROCEDURE 2: Flash Reprogram PCM NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 3343 c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select 'Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 3344 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications Spark Plug Resistance - 3.3/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 3347 Spark Plug: Mechanical Specifications Spark Plug - 3.3L/3.8L Torque Spark Plug Torque ............................................................................................................................... ................................................ 13 ft. lbs. (17.5 N.m) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3348 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. .................................................................RE14PLP5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3349 Spark Plug: Description and Operation STANDARD 4 CYLINDER All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Refer to Specifications for gap and type of spark plug. PLATINUM PLUGS The V6 engines use platinum resistor spark plugs. They have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. For spark plug identification and specifications, refer to Specifications. Do not use man ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Platinum Pads Setting Spark Electrode Gap When the spark plugs use a single or double platinum tips and they have a recommended service life of 100,000 miles for normal driving conditions per Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3350 schedule A. The spark plugs have a recommended service life of 75,000 miles for severe driving conditions per schedule B. A thin platinum pad is welded to both or just the center electrode end(s) as shown. Extreme care must be used to prevent spark plug cross threading, mis-gapping and ceramic insulator damage during plug removal and installation. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3351 Spark Plug: Service and Repair REMOVAL When replacing the spark plugs and spark plug cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. Always remove cables by grasping at the boot, rotating the boot 1/2 turn, and pulling straight back in a steady motion. 1. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. 2. Remove the spark plug using a quality socket with a foam insert. 3. Inspect the spark plug condition. INSTALLATION When replacing the spark plugs and spark plug cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. 1. Coat threads of spark plug with anti-seize. Be sure not to get anti-seize ANYWHERE BUT ON THE THREADS OF THE SPARK PLUG as shown. 2. To avoid cross threading, start the spark plug into the cylinder head by hand. 3. Tighten spark plugs to 17.5 N.m (13 ft. lbs.) torque. 4. Install spark plug cables over spark plugs. A click will be heard and felt when the cable properly attaches to the spark plug. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Cylinder Compression Pressure Cylinder Compression Pressure Minimum Compression Pressure 100 psi Maximum Variation Between Cylinders 25 % Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3355 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE TEST The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine reaches normal operating temperature. Select a route free from traffic and other forms of congestion, observe all traffic laws, and accelerate through the gears several times briskly. 3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicators fouled, hot, oily, etc. Record cylinder number of spark plug for future reference. 4. Remove the Auto Shutdown (ASD) relay from the PDC. 5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gauge adaptor Special Tool 8116 or the equivalent, into the # 1 spark plug hole in cylinder head. Connect the 0-500 psi (Blue) pressure transducer (Special Tool CH7059) with cable adaptors to the DRBIII. 7. Crank engine until maximum pressure is reached on gauge. Record this pressure as # 1 cylinder pressure. 8. Repeat the previous step for all remaining cylinders. 9. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 10. If one or more cylinders have abnormally low compression pressures, repeat the compression test. 11. If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3364 Intake Air Temperature Sensor: Connector Locations Inlet Air Sensors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 3365 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3366 Inlet Air Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3367 Intake Air Temperature Sensor: Description and Operation 3.3/3.8L IAT Sensor The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Specifications Specifications - Battery Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Specifications > Page 3371 Battery Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Specifications > Page 3372 Battery Temperature Sensor: Description and Operation (NGC Vehicles) The PCM incorporates a Battery Temperature Sensor (BTS) on its circuit board. The PCM uses the temperature of the battery area to control the charge system voltage. This temperature, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as temperature around the battery increases. For vehicles with 1.6L engine, there is no physical battery temp sensor in place to detect battery temp. Rather, an algorithm built in PCM is employed to predict battery temp using inlet air temp, vehicle speed, and coolant temp, among other signals. The PCM maintains the optimal output of the generator by monitoring battery voltage and controlling it to a range of 13.5 - 14.7 volts based on battery temperature. The system target voltage is 13.5 - 14.7 volts. However the actual voltage go below this during heavy electrical loads and generator speeds. Also the actual voltage can be lower than the target voltage between the battery and the battery voltage sense circuit, approximately 0.2 - 0.3 volts. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20°F. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor > Component Information > Specifications > Page 3373 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor is not serviced separately. If replacement is necessary, the PCM must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set Body Control Module: Customer Interest Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set NUMBER: 08-028-05 GROUP: Electrical DATE: May 28, 2005 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD JULY, 2005. SUBJECT: Flash: MIL Illumination, Remote Keyless Entry (RKE) Inoperative OVERVIEW: This bulletin involves reprogramming the Body Control Module (BCM) with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to CS vehicles built on or before May 7, 2005 (MDH 0507XX) and RS vehicles, built on or between July 26, 2004 (MDH 0726XX) through and including May 7, 2005 (MDH 0507XX), with a 4-connector BCM. SYMPTOM/CONDITION: ^ MIL Illumination ^ RKE inoperative ^ PCI Internal Fault DTC in BCM DIAGNOSIS: 1. With the ignition switch in the "RUN" position, determine the original software part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R)" standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 3382 g. Record the "Software part # " on the repair order for later reference. h. Check DTC's 2. If the Symptom/Condition is present, use the following table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "BCM part # ", recorded in "Diagnosis Step # 1, in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 4. Select the flash file. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 3383 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm Body Control Module: Customer Interest Electrical - Locks Inoperative/Liftgate Triggers Alarm NUMBER: 08-040-04 GROUP: Electrical DATE: December 9, 2004 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD FEBRUARY, 2005. SUBJECT: Flash: Driver And Passenger Power Door Lock Switches Inoperative And Opening the Liftgate Triggers The Theft Alarm OVERVIEW: This bulletin involves selectively erasing and reprogramming the Body Control Module (BCM) with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to 2005 vehicles equipped with Power Locks only (sales code JPB) and 2004 2005 vehicles equipped with Power Locks, Power Liftgate, and Security Alarm (sales codes JPB, JRC and LSA respectively). SYMPTOM/CONDITION: The vehicle operator may describe: ^ The alarm sounds erroneously when opening the power liftgate using the key fob while the Vehicle Theft Alarm (VTA) is armed. ^ The driver's and/or passenger's door lock switches are inoperative. The technician may find "Left Unlock Output Failure" and/or "Right Unlock Output Failure" Diagnostic Trouble Codes (DTC's) in the BCM. DIAGNOSIS: 1. Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. With the ignition switch in the "RUN" position, determine the original part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" g. Record the "Software part # " on the repair order for later reference. h. Check DTC's Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm > Page 3388 3. If the vehicle operator describes or experiences the Symptom/Condition, use the table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "Software part # " recorded during "Diagnosis" in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 4. Select the calibration. 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm > Page 3389 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition to the "Run" position (engine not running). 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. 13. Verify that the problem cannot be repeated by cycling the ignition switch OFF/ON and actuating both door lock switches a few times. If any door lock failure still persists then further diagnosis is necessary. Verify the BCM "Software p/n" was updated to the new software p/n using Diagnosis Step # 2. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, PCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set Body Control Module: All Technical Service Bulletins Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set NUMBER: 08-028-05 GROUP: Electrical DATE: May 28, 2005 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD JULY, 2005. SUBJECT: Flash: MIL Illumination, Remote Keyless Entry (RKE) Inoperative OVERVIEW: This bulletin involves reprogramming the Body Control Module (BCM) with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to CS vehicles built on or before May 7, 2005 (MDH 0507XX) and RS vehicles, built on or between July 26, 2004 (MDH 0726XX) through and including May 7, 2005 (MDH 0507XX), with a 4-connector BCM. SYMPTOM/CONDITION: ^ MIL Illumination ^ RKE inoperative ^ PCI Internal Fault DTC in BCM DIAGNOSIS: 1. With the ignition switch in the "RUN" position, determine the original software part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R)" standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 3395 g. Record the "Software part # " on the repair order for later reference. h. Check DTC's 2. If the Symptom/Condition is present, use the following table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "BCM part # ", recorded in "Diagnosis Step # 1, in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 4. Select the flash file. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 3396 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm Body Control Module: All Technical Service Bulletins Electrical - Locks Inoperative/Liftgate Triggers Alarm NUMBER: 08-040-04 GROUP: Electrical DATE: December 9, 2004 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD FEBRUARY, 2005. SUBJECT: Flash: Driver And Passenger Power Door Lock Switches Inoperative And Opening the Liftgate Triggers The Theft Alarm OVERVIEW: This bulletin involves selectively erasing and reprogramming the Body Control Module (BCM) with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to 2005 vehicles equipped with Power Locks only (sales code JPB) and 2004 2005 vehicles equipped with Power Locks, Power Liftgate, and Security Alarm (sales codes JPB, JRC and LSA respectively). SYMPTOM/CONDITION: The vehicle operator may describe: ^ The alarm sounds erroneously when opening the power liftgate using the key fob while the Vehicle Theft Alarm (VTA) is armed. ^ The driver's and/or passenger's door lock switches are inoperative. The technician may find "Left Unlock Output Failure" and/or "Right Unlock Output Failure" Diagnostic Trouble Codes (DTC's) in the BCM. DIAGNOSIS: 1. Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. With the ignition switch in the "RUN" position, determine the original part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" g. Record the "Software part # " on the repair order for later reference. h. Check DTC's Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm > Page 3401 3. If the vehicle operator describes or experiences the Symptom/Condition, use the table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "Software part # " recorded during "Diagnosis" in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 4. Select the calibration. 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm > Page 3402 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition to the "Run" position (engine not running). 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. 13. Verify that the problem cannot be repeated by cycling the ignition switch OFF/ON and actuating both door lock switches a few times. If any door lock failure still persists then further diagnosis is necessary. Verify the BCM "Software p/n" was updated to the new software p/n using Diagnosis Step # 2. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, PCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 3405 Body Control Module: Connector Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 3406 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 3407 Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3410 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3411 Figure 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3412 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3413 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3414 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3415 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3416 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3417 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3418 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3419 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3420 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3421 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3422 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3423 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3424 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3425 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3426 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and an Electrostatic Discharge Symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3427 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3428 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3429 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3430 Body Control Module: Connector Views Body Control Module C1 Body Control Module C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3431 Body Control Module C3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3432 Body Control Module C4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3433 Body Control Module C5 (early Build) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3434 Body Control Module: Electrical Diagrams Non-memory Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3435 Memory Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3436 Occupant Restraint Controller - Highline Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3437 Occupant Restraint Controller - Lowline Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3438 Occupant Classification System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3439 Premium Audio System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3440 Base Audio System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3441 CD Changer DVD/CD Changer Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3442 Remote Radio Controls Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3443 Front ATC - LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3444 Front ATC - RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3445 Rear ATC - Three Zone Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3446 Diesel Cabin Heater Assist (DCHA) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3447 Communication Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3448 PCM Communication - NGC ECM And Cabin Heater Assist Communication - Diesel Only Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3449 Door Ajar System With Power Sliding Doors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3450 Door Ajar System Without Power Sliding Doors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3451 Exterior Lighting Horn System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3452 Ignition Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3453 Integrated Power Module/body Control Module Power And Grounds Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3454 Instrument Cluster - Base Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3455 Instrument Cluster And Message Center (export, LHD) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3456 Instrument Cluster And Message Center (export,RHD) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3457 Interior Lighting Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3458 Base Manual Temperature Control System, LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3459 Base Manual Temperature Control System. RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3460 Dual-zone And Three Zone(front) Manual Temperature Control System, LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3461 Dual-zone Zone(front) Manual Temperature Control System, RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3462 Three Zone Rear Manual Temperature Control System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3463 Front Blower Motor - RS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3464 Front Blower Motor - RG Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3465 Rear Blower Motor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3466 Memory System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3467 Overhead Console Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3468 Park Assist Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3469 Power Door Looks/RKE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3470 LHD (export Only) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3471 RHD (export Only) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3472 Power Liftgate System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3473 Lift Power Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3474 Right Power Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3475 Power Sliding Door And Liftgate Switches Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3476 Rear Defog/Heated Mirror Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3477 Hands Free Phone - With CD Changer Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3478 Hands Free Phone - With CD/DVD Changer Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3479 Vehicle Theft Security System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3480 Thatcam Alarm System (export Only) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3481 Wipers - Front And Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3482 A/C - Lef Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3483 Le - Tr 8W-45-2 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3484 8w-45-2 Next Diagram See: 8W-45-3 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-3 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3485 8w-45-3 Next Diagram See: 8W-45-4 Previous Diagram See: 8W-45-2 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3486 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-4 Next Diagram See: 8W-45-5 Previous Diagram See: 8W-45-3 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3487 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-5 Next Diagram See: 8W-45-6 Previous Diagram See: 8W-45-4 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3488 8W-45-6 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-6 Next Diagram See: 8W-45-7 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3489 Previous Diagram See: 8W-45-5 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-7 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3490 8w-45-7 Next Diagram See: 8W-45-8 Previous Diagram See: 8W-45-6 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-8 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3491 8w-45-8 Next Diagram See: 8W-45-9 Previous Diagram See: 8W-45-7 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3492 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-9 Next Diagram See: 8W-45-10 Previous Diagram See: 8W-45-8 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3493 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-10 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3494 Next Diagram See: 8W-45-11 Previous Diagram See: 8W-45-9 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-11 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3495 8w-45-11 Next Diagram See: 8W-45-12 Previous Diagram See: 8W-45-10 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-12 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3496 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-12 Next Diagram See: 8W-45-13 Previous Diagram See: 8W-45-11 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3497 Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-13 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-13 Next Diagram See: 8W-45-14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3498 Previous Diagram See: 8W-45-12 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-14 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3499 8w-45-14 Next Diagram See: 8W-45-15 Previous Diagram See: 8W-45-13 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3500 8W-45-15 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-15 Next Diagram See: 8W-45-16 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3501 Previous Diagram See: 8W-45-14 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-16 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3502 8w-45-16 Next Diagram See: 8W-45-17 Previous Diagram See: 8W-45-15 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-17 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3503 8w-45-17 Next Diagram See: 8W-45-18 Previous Diagram See: 8W-45-16 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-18 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-18 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3504 Next Diagram See: 8W-45-19 Previous Diagram See: 8W-45-17 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-19 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3505 8w-45-19 Next Diagram See: 8W-45-20 Previous Diagram See: 8W-45-18 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-20 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3506 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-19 Previous Diagram See: 8W-45-19 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3507 Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced as an assembly only. Attempting to remove or repair certain system subcomponents may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 3510 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description Body Control Module: Description and Operation System Description IDENTIFICATION OF SYSTEM The vehicle systems that are part of the body system are: - Adjustable Pedal System (APS) - Airbag System - Audio - Automatic Temperature Control - Cabin Heater - Chime - Communication - Door Ajar System - Electrically heated system - Exterior lighting - Instrument Cluster - Interior Lighting - Manual Temperature Control - Memory Seat - Overhead Console - Park Assist - Power Door Lock/RKE - Power Folding Mirrors - Power Sliding Doors - Power Liftgate - Power windows - Telecommunications (hands free phone) - Tire Pressure Monitor System (TPMS) - Vehicle Theft Security System (VTSS) - Windshield Wiper and Washer SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 2005 RS and RG consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate modules. All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages addressed to it through binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the Communication Section of this general information. The Body Control Module (BCM) is located in the passenger compartment, attached to the bulkhead underneath the left side of the instrument panel. The BCM utilizes integrated circuitry and information carried on the Programmable Communications Interface (PCI) data bus network along with many hard wired inputs to monitor many sensor and switch inputs throughout the vehicle. In response to those inputs, the internal circuitry and programming of the BCM allow it to control and integrate many electronic functions and features of the vehicle through both hard wired outputs and the transmission of electronic message outputs to other electronic modules in the vehicle over the PCI data bus. The Body Control Module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the BCM is interfaced to the vehicle's serial bus communications network, referred to as the Programmable Communications Interface (PCI) bus. This network consists of the; - Powertrain Control Module (PCM) - Transmission Control Module (TCM) - Mechanical Instrument Cluster (MIC) - Occupant Restraint Controller (ORC) - Compass/Mini-Trip Computer (CMTC) - Electronic Vehicle Information Center (EVIC) - Controller Antilock Brake (CAB) - HVAC Control Module - Sliding Door Control Modules (driver and passenger side doors) - Power Liftgate Module (PLG) - Audio system equipped with RAZ, RBU, RBK, and RBB radios. - Sentry Key Remote Entry Module (SKREEM). - Side Impact Airbag Control Module (SIACM) - Memory Seat Module (MSM) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3513 - Sentry Key Immobilizer Module (SKIM) The BCM is operational when battery power is supplied to the module. The BCM provides the following features: - Power Door Locks - Automatic Door Locks - Battery Protection - The BCM will automatically turn off all exterior lamps after 3 minutes, and all interior lamps after 15 minutes after the ignition is turned off, if they are not turned off by the driver. - Chime Control - Compass/Mini-Trip support. - Interior Lighting (Courtesy/Reading Lamps) - BCM Diagnostic Reporting - Electronic Liftgate Release (with Power Door Locks) - Exterior Lighting - Headlamp Time Delay (with/without Automatic Headlamps) - Illuminated Entry - Fade to Off Interior Lamps - This feature dims the interior lighting (courtesy lamps) gradually if the BCM does not receive any new inputs that would cause the interior lamps to remain on. - Pulse Width Modulated Instrument Panel Dimming - Door Lock Inhibit - This feature disables the door lock functions if the key is in the ignition and either front door is ajar. Pressing the Remote Keyless Entry (RKE) lock/unlock button under these conditions result in normal lock/unlock activation. Learned Features The BCM has the ability to LEARN additional features in the vehicle, provided the appropriate switch input and PCI data bus messages are received. Refer to the LEARNED FEATURES table. When replacing a BCM there are three modules available: - Base - Midline - RG - Export Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3514 The Midline controller is used on vehicles that have Power Door Locks. If a vehicle is equipped with the Vehicle Theft Security System, the Midline controller becomes a Premium when the theft feature is enabled. CAUTION: Do not swap Body Control Modules between vehicles or body controller's off the shelf. The BCM has internal diagnostic capability that assists in diagnosing the system error. When an OPEN or a SHORT circuit exists, the diagnostic tool can be used to read the BCM faults. The faults are very descriptive in identifying the appropriate feature that has faulted. The only two faults that the BCM logs that conclude the replacement of a BCM are faults; - # 01 - Internal BCM failure (replace BCM) - # 1F - J1850 Internal Hardware Failure (replace BCM) Otherwise the appropriate diagnostic procedures for each of the features should be taken when the BCM logs a fault. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3515 Body Control Module: Description and Operation Functional Operation Adjustable Pedals System The Adjustable Pedals are designed to enable the fore and aft repositioning of the brake and accelerator pedals. This results in improved ergonomics in relation to the steering wheel for taller and shorter drivers. Being able to adjust the pedal positions also allows the driver to set steering wheel tilt and seat positions to the most comfortable position available. The positions can be adjusted without compromising safety or comfort in actuating the pedals. Repositioning the pedals does not change the effort required for actuation. Changing of pedal position is accomplished by means of a motor. Operating the adjustable pedal switch activates the pedal drive motor. The pedal drive motor changes the position of the brake and accelerator pedals. The pedal can move rearward or forward. The pedals are moved to a position that is most comfortable for the driver. The accelerator and brake pedals are moved at the same rate to ensure synchronization. Neither the motor nor mechanisms are subject to mechanical stress of brake or accelerator application. The adjustable pedals feature is available on a non-memory/memory-equipped vehicle. The non-memory system consists of a mechanical switch that allows pedal travel adjustment. The IPM controls the Fused B+ circuit voltage to the adjustable pedals switch through the adjustable pedals relay. The circuit opens when the IPM detects an active cruise control state or when the vehicle is in reverse. The adjustable pedals control switch is located on the right side steering column shroud. The switch is hardwired directly to the adjustable pedals motor. When the operator actuates the switch to adjust the pedals, voltage is applied to the adjustable pedals motor allowing adjustment. The memory system, known as the Memory Seat Mirror Adjustable Pedal Module (MSMAPM), is located under the driver's seat and controls the adjustable pedals. The adjustable pedals control switch is located on the right side steering column shroud. The switch is hardwired directly to the MSMAPM. When the operator actuates the switch to adjust the pedals, the MSMAPM controls the adjustable pedals motor movement with input from the adjustable pedals sensor. This sensor allows pedal adjustment and memory functions to be recalled from the driver door mounted memory buttons or the RKE transmitters. The adjustable pedals will not operate when in an active cruise control state or when the vehicle is in reverse. Part 1 of 2 AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM AND OCCUPANT CLASSIFICATION SYSTEM The Airbag System contains the following components: Occupant Restraint Controller (ORC), Air-bag Warning Indicator, Clockspring, Driver and Passenger dual squib Airbags, Driver and Passenger Seat belt Tensioner (SBT), Driver and Passenger Hall-effect Seat Belt Buckle Switches (SBS), Left and Right Side Curtain Airbags, and Front and Side Impact Sensors. The ORC also monitors the Occupant Classification System (OCS) for the presence of a passenger in the front outer seat. The Occupant Classification System contains the following components: Occupant Classification Module (OCM), Bladder and Sensor, Belt Tension Sensor, and Passenger Airbag off Indicator. The Occupant Restraint Controller (ORC) supports staged airbag deployment and remote impact sensing. Staged deployment is the ability to trigger airbag system squib inflators individually as needed to provide the appropriate restraint for the severity of the impact. The ORC has four major functions: PCI Bus communications, onboard diagnostics, impact sensing, and component deployment. The ORC also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the front airbag components for two seconds following a battery disconnect or failure during an impact. The ORC is secured to the floor panel transmission tunnel below the instrument panel inside the vehicle. The ORC cannot be repaired or adjusted. The ORC sends and/or receives PCI Bus messages with the Instrument Cluster (MIC), Body Control Module (BCM), and Powertrain Control Module (PCM). Diagnostic trouble codes will be set if the communication with these modules is lost or contains invalid information. The microprocessor in the ORC monitors the front impact sensor signals and the airbag system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sends a message to the instrument cluster via PCI bus to turn on the Airbag Warning Indicator. The ORC can set both active and stored diagnostic trouble codes to aid in diagnosing system problems. See DIAGNOSTIC TROUBLE CODES. The ORC uses an internal accelerometer, two front sensors and six side impact sensors, to sense the rate of vehicle deceleration and provide verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ORC microprocessor determines when the deceleration rate is severe enough to require airbag system protection. The ORC also uses the driver and passenger seat belt switch status (buckled or unbuckled) to determine the level of driver airbag deployment, low medium or high. When the programmed conditions are met, the ORC sends an electrical signal to deploy the appropriate airbag system components. WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS CAN RESULT IS ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. - NEVER STRIKE OR KICK THE OCCUPANT RESTRAINT CONTROLLER, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. The Airbag Warning Indicator is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3516 turned to the run or start position, the ORC performs a lamp check by turning the Airbag Warning Indicator on for 6-8 seconds. After the lamp check, if the indicator turns off, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes off, there is usually an intermittent problem in the system. DRIVER AIRBAG The airbag protective trim cover is the most visible part of the driver side airbag system. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. When supplied with the proper electrical signal, the inflator or inflators discharge the gas directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE DRIVER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 17236.89 kPa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. CAUTION: Deployed Front Air Bags may or may not have live pyrotechnic material within the air bag inflator. Do not dispose of Driver and Passenger Airbags unless you are sure of complete deployment. Please refer to the Hazardous Substance Control System for Proper Disposal. Dispose of deployed air bags in a manner consistent with state, provincial, local, and federal regulations. Use the following table to identify the status of the Airbag Squib. AIRBAG SQUIB STATUS 1. Using a DRBIII(R) read Airbag DTC's If the following active codes are present: If neither of the following codes is an active code: ACTIVE DTC SQUIB STATUS Driver squib 1 open Driver Squib 2 open Status of Airbag is Unknown. CLOCKSPRING The clockspring is mounted on the steering column under the steering wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wiring and the driver airbag, the horn, and the vehicle speed control switches if equipped. The clockspring Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3517 must be properly centered when it is reinstalled on the steering column following any service procedure, or it could be damaged. The clockspring cannot be repaired and it must be replaced. PASSENGER AIRBAG The front passenger airbag is equipped with dual stage squib inflators. When supplied with the proper electrical signal the inflator or inflators discharge the gas directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS INERT GAS PRESSURIZED TO 17236.89 kPa (2500 PSI). DO NOT ATTEMPT TO IS MANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR.DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. AIRBAG SQUIB STATUS 1. Using a DRBIII(R) read Airbag DTC's If the following active codes are present: If neither of the following codes is an active code: ACTIVE DTC SQUIB STATUS Passenger squib 1 open Passenger squib 2 open Status of Airbag is Unknown. CAUTION: Deployed Front Air Bags may or may not have live pyrotechnic material within the air bag inflator. Do not dispose of Driver and Passenger Airbags unless you are sure of complete deployment. Please refer to the Hazardous Substance Control System for Proper Disposal. Dispose of deployed air bags in a manner consistent with state, provincial, local, and federal regulations. Use the following table to identify the status of the Airbag Squib. SEAT BELT TENSIONER (SBT) The driver and passenger seat belt (buckle) tensioners are mounted to the inboard side of the front seats. The seat belt buckle and seat belt switch are connected directly to the seat belt tensioner cable. At the onset of an impact event the ORC uses the seat belt tensioner to rapidly retract the seat belt buckles. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. The seat belt tensioner cannot be repaired, if damaged or defective it must be replaced. The ORC continuously monitors the resistance of the seat belt tensioner circuits for open and shorted conditions. SEAT BELT SWITCHES (SBS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3518 The hall-effect driver and passenger seat belt switches provide the seat belt status, buckled or unbuckled, via hardwired inputs to the ORC. If the seat belt switch is damaged or defective the seat belt tensioner must be replaced. The ORC continuously monitors the seat belt switch circuits for open and shorted conditions. DRIVER KNEE BLOCKER AIRBAG The most visible part of the Driver Knee Blocker Airbag is the knee blocker trim cover. The knee blocker trim cover and airbag are mounted directly to the instrument panel structure below the steering column. When supplied with the proper electrical signal, the inflator discharges the gas directly into the airbag. The airbag cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: - DO NOT ATTEMPT TO MODIFY ANY PART OF YOUR ADVANCED AIRBAG SYSTEM. THE AIRBAG MAY INFLATE ACCIDENTALLY OR MAY NOT FUNCTION PROPERLY IF MODIFICATIONS ARE MADE. TAKE YOUR VEHICLE TO AN AUTHORIZED DEALER FOR ANY ADVANCED AIRBAG SYSTEM SERVICE. IF YOU'RE SEAT INCLUDING YOUR TRIM COVER AND CUSHION NEEDS TO BE SERVICED IN ANY WAY (INCLUDING REMOVAL OR LOOSENING/TIGHTENING OF EAT ATTACHMENT BOLTS), TAKE THE VEHICLE TO YOUR AUTHORIZED DEALER. ONLY MANUFACTURER APPROVED SEAT ACCESSORIES MAY BE USED. CONTACT YOUR AUTHORIZED DEALER IF IT IS NECESSARY TO MODIFY AN ADVANCED AIRBAG SYSTEM FOR PERSONS WITH DISABILITIES. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. FRONT AND SIDE IMPACT SENSOR The front and side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, and combined with the ORC Accelerometer Sensor provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller. The ORC microprocessor continuously monitors all of the front and side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a system fault, it sets a Diagnostic Trouble Code and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor signal and ground circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor signal circuit. If the sensor is dropped it must be replaced. CAUTION: Do not remove or install the impact sensors while the sensor is connected to the vehicle wiring. OCCUPANT CLASSIFICATION SYSTEM A non-calibrated Occupant Classification Module (OCM) is the only component of the Occupant Classification System (OCS) that is available for separate service replacement, as outlined in the procedures that follow. The OCS components of the passenger side front seat cushion including the cushion frame, springs, pad, seat weight bladder and pressure sensor, seat cushion foam and the OCM are a factory-calibrated and assembled unit. Once this unit is connected to a vehicle electrically, the calibration settings are uploaded from the OCM and stored in the memory of the Airbag Control Module (ORC). If only the OCM is subsequently replaced, the new, non-calibrated OCM learns the proper calibration settings from the ORC after it is connected to the vehicle electrically. If any of the remaining OCS components of the passenger side, front seat cushion require replacement, they are serviced only as a factory calibrated, assembled, and tamper-evident service replacement package. This package includes the assembled frame, springs, pad, seat weight bladder and pressure sensor, foam, wiring and a calibrated OCM. When installing this package, always replace all of the existing components with the new components as a unit. Do not attempt to separate or disconnect any of the new OCS components contained in the service replacement package from each other, and do not attempt to reuse any of the replaced components in this or any other vehicle. Once any of the original factory-installed components except the OCM have been replaced with the service replacement package components, the OCM can only be serviced by replacing the entire passenger side front seat cushion unit with another complete service replacement package. CAUTION: On vehicles equipped with the Occupant Classification System (OCS), never replace both the Airbag Control Module (ORC) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one. Then perform the supplemental restraint verification test before replacing the other. Both the ORC and the OCM store OCS calibration data, which they transfer to one another when one of them is replaced. If both are replaced at the same time, an irreversible fault will be set in both modules. The OCM is subsystem of the Airbag Control Module (ORC). Therefore the OCM bus message updates the ORC with the front passenger seat information via PCI Bus message. The ORC then controls the Passenger Off indicator and the Airbag Warning Indicator to provide system onboard diagnostic feedback. All OCS wiring repairs are prohibited; when wiring problems are diagnosed a Bladder Repair Kit is the only approved repair. Part 2 of 2 PASSENGER AIRBAG OFF INDICATOR Vehicles equipped with the Occupant Classification System (OCS) include a passenger airbag off indicator located in the Switch Bank in the center of the instrument panel. Vehicles without OCS have a blank lens installed in the instrument panel. At ignition on, for a system test, the ORC low side driver grounds a yellow Light Emitting Diode (LED) circuit causing the PASS AIRBAG OFF Indicator text and icon to be illuminated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3519 SEAT WEIGHT SENSOR Vehicles equipped with the Occupant Classification System (OCS) have a seat weight bladder and pressure sensor unit that is integral to the passenger front seat cushion. The pressure sensor receives a nominal five volts and a ground through dedicated hardwired circuits from the OCM. The OCM then monitors the pressure sensor output voltage. SEAT BELT TENSION SENSOR - BTS The Belt Tension Sensor (BTS) is designed to measure belt tension as an input to a passenger Occupant Classification System (OCS). It is used to detect high cinch loads associated with child seats and compensate for the seat cushion load to correctly classify occupant size. When a load is applied to the seat belt, the belt tension sensor measures the load. As the load changes, the circuitry of the belt tension sensor changes the output voltage of the sensor. The belt tension sensor receives a nominal five volts and a ground through dedicated hardwired circuits from the OCM. The OCM then monitors the belt tension sensor output voltage on a dedicated hardwired data communication circuit. If the vehicle has experienced any impact(s) resulting in deployment of a pyrotechnic device of any kind (airbag, seatbelt tensioner, side curtain, etc.) within the vehicle, the entire passenger seat belt retractor assembly, including the BTS, shall be replaced. Additionally, if the seat belt webbing has become cut, frayed, or worn; or if the stitching has become damaged in any way, the entire passenger seat belt retractor assembly, including the BTS, shall be replaced. The belt tension sensor cannot be repaired and, if faulty or damaged, the entire passenger side front seat belt and retractor unit must be replaced. The OCM Verification Test will also provide a BTS Verification procedure to verify the BTS function. This verification procedure requires the Miller Special Tool #8828. BLADDER REPAIR KIT There are only three replaceable components in the OCS, Occupant Classification Module, Bladder Repair Kit and the Passenger Airbag OFF Indicator. The Bladder repair kit contains the OCS bladder, wire harnesses, pressure sensor (Seat Weight Sensor), module, seat cushion and other related structural and sound deadening components. The module and sensor connector must have a Tamper Evident material installed on the service kit module and sensor connectors. This material provides visible evidence that the assembly has been separated after the calibration process was completed. Do not install a Bladder Repair Kit if it appears that any of the components have been disconnected. The OCM can be replaced if the Airbag Control Module has uploaded the seat calibration into memory in a previous ignition cycle and the new OCM has a blank VIN and no calibration data stored in memory. NOTE: - An OCM can only be replaced in a passenger front seat if the seat is equipped with the original OCS module, bladder, sensor and wiring. - Servicing the OCS may create additional active and stored trouble codes that must be resolved before the vehicle can be returned to the owner. The OCS Verification Test will also set active DTC's if the procedure is not completed successfully. The Miller Special Tool, MRL-9077 and the DRBIII are needed to successfully complete the system Verification Test. The DRBIII(R) may report the following NEW DRBIII(R) FEATURE ORC Menu The DRBIII(R) ORC System Test screen will display the following: 2VIN verification - Original VIN and Current VIN 2PCM Monitor - PCM Active On The Bus or PCM Not Active On The Bus The DRBIII(R) ORC Input/Outputs screen will display the following: - OCM Status: Seat Class 0 (Empty) - Seat Cass 1 (Rear Facing Infant car Seat or RFIS) - Seat Class 2 (6 year old or Child) - Seat Class 3 (greater than or equal to 5th Percentile Female) - Seat Class 4 (less than 5th Percentile Female) - Seat Class 5 (Undetermined) The DRBIII(R) ORC Miscellaneous screen will display the following: - Configure Airbag On-Off Switch 1. No Airbag On-Off Switch 2. Pass OCM Only OCS Menu The DRBIII(R) OCM Input/Output screen will display the following: - OCS Status - 90, 919, 929, 939, 949, 959 The DRBIII(R) OCM Sensors screen will display the following: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3520 - Bladder Output - XXX A/D counts - Pas BTS Output - XXX A/D counts The DRBIII(R) OCM OCS Info Monitor screen will display the following: - Pass BTS -- Enabled or Disabled System Verification The DRBIII(R) OCM System Test screen will display the following: - PCM Monitor - PCM Active On The Bus or PCM Not Active On The Bus - Clear VIN Mismatch - Clear VIN Mismatch Complete - VIN Verification - Original VIN and Current VIN Clear VIN Mismatch - OCS Verification - OCS Verification Test process errors: Test In Progress Mode 33 Not Supported Subfunction not supported Test Busy - Repeat Test Conditions for Test Not Correct Routine Already Running Routine was Never Started Press any key to continue, then restart the verification test. Test failed conditions: Test Failed - Active DTC's Present Test Failed - Seat is Empty Test Failed - Seat Occupied Test Failed - Weight Above Threshold Test Failed - Weight Below Threshold Test Failed - Temperature Out of Range Test Failed - Seat Pressure Too High Test Failed - Seat Pressure Too Low Test Failed - Seat Pressure Not Stable Test Failed - Temperature Out of Range Test Failed - Seat Pressure Too Low Test Failed - Power Up Time Too Short Test Failed - Power Up Time Too Long Test Failed - K Empty Count is 0 Test Failed - No EOL Calibration Test Failed - K Allow is FF Allow the vehicle seat and interior temperature to stabilize, check voltage supplies and repair any other active DTC's before restarting the System Verification test. The OCS has been Verified or The OCS has NOT been Verified WARNING: - TO AVOID PERSONAL INJURY OR DEATH, TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING. - TO AVOID PERSONAL INJURY OR DEATH, TURN THE IGNITION ON, THEN RECONNECT THE BATTERY. - TO AVOID PERSONAL INJURY OR DEATH ON VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS), ONLY THE OCCUPANT CLASSIFICATION MODULE (OCM) AND THE PASSENGER SEAT BLADDER AND CUSHION SERVICE KIT ARE THE ONLY PARTS SERVICED. - IF THE OCCUPANT CLASSIFICATION MODULE IS DROPPED AT ANY TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. TO AVOID PERSONAL INJURY OR DEATH ON VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS), ONLY THE OCCUPANT CLASSIFICATION MODULE (OCM) AND THE SEAT CUSHION TRIM MAY BE SERVICED SEPARATELY. ALL OTHER COMPONENTS OF THE PASSENGER SIDE FRONT SEAT CUSHION ASSEMBLY MUST BE SERVICED ONLY AS A COMPLETE FACTORY-CALIBRATED, ASSEMBLED AND TAMPER-EVIDENT SERVICE REPLACEMENT PACKAGE. THIS PACKAGE INCLUDES THE FRAME, SPRINGS, PAD, BLADDER AND PRESSURE SENSOR, FOAM, WIRING AND A CALIBRATED OCM. WHEN INSTALLING THIS PACKAGE ALWAYS REPLACE ALL OF THE EXISTING COMPONENTS WITH THE NEW COMPONENTS AS A UNIT. DO NOT ATTEMPT TO SEPARATE OR DISCONNECT Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3521 ANY OF THE NEW OCS COMPONENTS IN THE SERVICE REPLACEMENT PACKAGE FROM EACH OTHER, AND DO NOT ATTEMPT TO REUSE ANY OF THE REPLACED COMPONENTS IN THIS OR ANY OTHER VEHICLE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN FAILURE OF THE PASSENGER AIRBAG TO DEPLOY WHEN REQUIRED, OR IN PASSENGER AIRBAG DEPLOYMENT WHEN NOT REQUIRED. SPECIAL TOOLS Some airbag diagnostic tests will require the use of special tools, airbag load tools, 8443 for testing squib circuits and the Occupant Classification Seat Weight Tool 9077. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of a Driver or Passenger Airbag, curtain airbag, clockspring, or seat belt tensioner (use a jumper if needed). Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective component has been removed from the system and should be replaced. If the DTC is still active, continue this process until all components in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed the squib wiring can be tested for open and shorted conditions. DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes with the DRBIII(R). This will direct you to the specific test(s) that must be performed. In certain test procedures diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The code becomes active as soon as the malfunction is detected or key-on, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the Occupant Restraint Controller checks that circuit or component. It is impossible to erase an active code. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. STORED CODES Airbag codes are automatically stored in the ORC's memory as soon as the malfunction is detected. A stored code indicates there was an active code present at some time. When a trouble code occurs, the Airbag Warning Indicator illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). Once the code is no longer active, the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected will be displayed. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. The ignition cycle counter will be reset and diagnostic trouble code will continue to be a stored code, If the malfunction reoccurs before the count reaches 100. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. Maintain a safe distance from all airbags while performing the following inspection. If no obvious problems are found, erase stored codes, and with the ignition on wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Audio System Some of the radios are on the PCI Bus system. The PCI Bus inputs into the radio are used for VF dimming, remote steering wheel controls and cabin EQ preference. PCI Bus outputs from the radio are used for the Name Brand Speaker (NBS) relay activation, as well as cabin EQ preference. The radios have the capability of containing multiple vehicle unique equalization curves (cabin EQ preferences) within the radio. These curves will reside in the radio's flash memory. The radio is capable of storing up to 20 unique equalization curves. The latent curves can be selected via the Front Control Module transmitting a PCI Bus message to the radio in response to a radio request for equalization message. Upon receipt of a valid equalization select message response, the radio will switch to output the corresponding equalization curve. All the radios are capable of displaying faults and allowing certain actuation tests through the use of the DRBIII(R). When attempting to perform PCI Bus diagnostics, the first step is to identify the radio in use in the vehicle. When trouble shooting output shorts or 'output' error messages, the following applies: On radios without an external amplifier, the term output refers to the path between the radio and the speaker. This type of circuit can be monitored all the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3522 way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio, or wiring could be at fault. On radios with an external amplifier, the term 'output' refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. NAVIGATION RADIO The optional navigation radio system receives GPS signals from up to eight satellites to display the position and direction of the vehicle. Map information is supplied through a DVD-ROM. An electronic gyrosensor and the vehicle's speed sensor enable the system to display the present vehicle position even in locations where GPS signals may be blocked. When a destination is selected, the navigation system uses information from the map to quickly calculate a route. As the vehicle is driven along the chosen route, the operator is guided with pictorial displays and voice prompts. For complete operating instructions, refer to the manual included with the vehicle. REMOTE RADIO CONTROLS These radios can be controlled via remote radio switches (optional). These switches are located on the back side of the steering wheel. They control mode, preset, seek up, seek down, volume up and volume down functions. These functions are inputs to the Body Control Module and can be read with the DRBIII(R) under 'body computer'. The switches are a multiplexed signal to the BCM. The radio control MUX circuit is a 5 volt line that is pulled to ground through different value resistors built into the switches. This causes a voltage drop to be seen by the BCM and it sends a specific message to the radio on the PCI Bus circuit. The radio then responses to the message. This circuit is fairly simple to troubleshoot. The circuit must be complete from the switches in the steering wheel to the BCM. The ground must be complete so that the switches can cause the voltage drop for the BCM to see. The circuit passes through the clockspring so continuity through this devise must be verified. CD CHANGER The new in-dash CD Changer is designed to fit into the existing cubby bin in the center stack. This new cartridge-less CD Changer is controlled by your radio, and allows you to individually load up to four discs at a time. However, due to its compact design, the CD Changer can only carry out one operation at a time. For example, you can not load a new disc while playing another at the same time. Each operation happens sequentially. The radio unit installed with your system provides control over all features of the CD Changer with the exception of the CD load and eject functions, which are controlled by buttons located on the front of the CD Changer. The radio also supplies the power, ground, PCI Bus, left and right speaker output through a single DIN cable. All features you would expect, such as Disc Up/Down, Track Up/ Down, Random and Scan are controlled by the radio, which also displays all relevant CD Changer information on the radio display. The CD Changer contains a Load/Eject button and an indicator light for each of the four disc positions. The individual light indicates whether a CD is currently loaded in that particular chamber of the CD Changer. Pressing the individual Load/Eject button for a particular chamber will eject a disc currently present in that chamber. If the chamber is currently empty, actuating the Load/Eject button will position that chamber to receive and load a new disc in that chamber. DVD/CD CHANGER The DVD/CD Changer (if equipped) is located in the instrument panel below the radio. The DVD/CD Changer can hold one DVD at a time. Three RCA jacks on the front of the unit will allow the use of MP3 players, video systems or camcorders. Body Control Module The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (PCI). This network consists of the powertrain control module (PCM), the engine control module (ECM) diesel, the mechanical instrument cluster (MIC), the front control module (FCM), the occupant restraint controller (ORC), the occupant classification module (OCM), the overhead console, the ABS module, the hands free module (HFM), the park assist module, the HVAC control module (ATC & MTC), the power sliding door (Left & Right) modules (PSD), the power liftgate module (PLG), the Audio system (which includes the Radio, DVD, CD Changer and Amplifier), the memory seat/mirror/ adjustable pedals module (MSMAPM), the RKE/ Thatcham alarm module (export), the transmission control module (Diesel only) and the sentry key remote entry module (SKREEM). The BCM is operational when battery power is supplied to the module. The body control module provides the following features: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3523 - Power Door Locks - Automatic Door Lock - Door Lock Inhibit - Central Locking (with VTSS Only) - Battery Protection - The BCM will automatically turn off all exterior lamps after 3 minutes and all interior lamps after 15 minutes after the ignition is turned off, if they are not turned off by the driver. - Chime Driver - Compass/Minitrip Support - Interior Lighting (Courtesy/Reading Lamps) - BCM Diagnostic Reporting - Electronic Liftgate Release (with Power Door Locks) - Exterior Lighting - Headlamp Time Delay (with/without Auto headlamps) - Automatic Headlamps (with electrochromatic mirror) - Illuminated Entry - Fade to Off This feature dims the interior lighting (courtesy lamps) gradually if the BCM does not receive any new inputs that would cause the interior lamps to remain on. - PWM Instrument Panel Dimming - Door Lock Inhibit This feature disables the door lock functions if the key is in the ignition and either front door is ajar. Pressing the RKE lock/unlock button under these conditions, result in normal lock/unlock activation. - Power Sliding Door Switch Inputs The BCM has 4 switch inputs for the power sliding door feature: Located in the overhead console are the Left and Right side sliding door switches to activate either or both sliding doors under the proper conditions. Also there are B-Pillar switches located on the Left and Right B-pillar posts. - Power Liftgate Switch Input The BCM has 1 Liftgate switch input located in the overhead console - Power Lockout Switch Input The BCM has 1 Lockout switch that when enabled will disable the B-Pillar sliding door switches from activating either sliding door when depressed. When replacing a body control module there are 2 modules available, a Base and a Midline. The Midline controller is used on vehicles that have Power Door Locks. If a vehicle is equipped with the Vehicle Theft Security System, the midline controller becomes a premium when the theft feature is enabled. NOTE: Do not swap the body control module between vehicles or body control modules off the shelf. Engineering does not recommend that service, dealers or the plant swap Body Control Modules (BCM) between vehicles or off the shelf. The BCM has internal diagnostic capability that assists in diagnosing the system. When an 'open' or a 'Short' circuit exists, the diagnostic tool can be used to read the BCM codes. The codes are very descriptive in identifying the appropriate feature that has faulted. The BCM also learns what features are on the vehicle and if modules are swapped the BCM could set false DTC's based on what it learned. Chime Warning System The BCM monitors the door/liftgate ajar switches, multifunction switches, headlight switch, ignition switch, PCI bus, and the diagnostic tool to perform various chime operations. The BCM uses a low-side driver to control the chime located in the cluster. The chime system provides the Driver with warning chimes for: - Seat belt - Exterior lights on - Key-in Ignition - Key-in Accessory - Engine temperature critical - Low washer fluid - Turn signals on - Dome light on - Low oil pressure - Any warning lamp announcement - High-speed warning Gulf Coast Countries (GCC) only The output sound intensity of the chime is approximately 72 decibels. CHIME PRIORITY Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3524 The following list indicates the priority of the chime when more than one chime is active at the same time: - Seat belt warning - High-speed warning Gulf Coast Countries (GCC) only - Turn signal on - Chime request - Warning lamp announcement The cluster is responsible to set priority on all warning lamp announcement chimes. CHIME ON CONDITIONS The following is a list of the chime warnings and when they will sound. Driver's Seatbelt Unbuckled: Sounds for approximately 6 ± 2 seconds when the ignition is turned on driver's seat belt is not buckled, as a reminder to the driver to buckle the seat belt. Exterior Lights On:Ignition is in the lock position, the driver door is ajar, and the headlight switch is left in any position, other than auto or off.The chime will sound as a warning to the driver until one of the above conditions is removed or until the battery protection time of 3 minutes has expired. Key-In Ignition: Ignition is in the lock position, driver door is ajar and the key is in the ignition. The chime will sound until one of the above conditions is removed or until the battery protection time of 15 minutes has expired. Turn Signal On: When the BCM detects a turn signal input continuously for 1.0 mile/0.6 km and the vehicle speed is greater than 15 mph/24 kph, the chime will sound until the specific turn signal is cancelled. Dome Lights On: Ignition is in the lock position, driver door ajar, and the dome light switch is left in the on position. The chime will sound until one of the above conditions is removed or until the battery protection time of 15 minutes has expired. Low Oil Pressure: The chime will sound when the engine is operating and the oil pressure drops below 4 psi/27.5 kPa. Engine Temperature Critical: The chime will sound when the engine is operating and the coolant temperature exceeds 252° F/122° C or 234° C/112° C(diesel). The chime is continuous at 257° F/ 125° C and will chime for 4 minutes and stop if the temperature drops below 255° F/123° C. Low Washer The chime will sound when the Fluid washer fluid drops below a specific level. Warning Lamp Announcement: A chime will sound to alert the driver to scan the instrument panel and overhead console to see which warning lamp is illuminated. The door/liftgate ajar warning lamp will appear without a chime if the vehicle is running and a door or the liftgate is opened. A chime will sound if the door or liftgate is still open and the vehicle speed is greater than 4 mph/6 kph. High-speed warning Gulf Coast Countries (GCC) only The chime will sound, acting as a warning to the driver that the vehicle speed has exceed 75 mph ± 2/120 kph ± 3. WARNING LAMP ANNOUNCEMENT Low Fuel Lamp: The cluster will request a single chime after the indicator is illuminated. Volt Lamp: The cluster will request a single chime after the indicator is illuminated. Oil Pressure Lamp: The cluster will request a single chime after illuminating the indicator above 450 rpm vehicle operation. Liftgate Ajar Lamp: The BCM determines when to chime for liftgate ajar. Fasten Seat Belt Lamp: The MIC will request a single chime from the BCM when the ignition is turned to the unlock/ run/start positions if the driver seat belt is not buckled and 2 seconds after seatbelt warning chime ends. Check Engine Lamp: The cluster will request a single chime after the indicator is illuminated. Low Washer Fluid Lamp: The cluster will request a single chime after the indicator is illuminated. Engine Temperature Lamp: The cluster will request a single chime when the indicator is first illuminated at 252° F/122° C. OTHER CHIME ON CONDITIONS Programming of an Additional Key Fob: A single cluster chime will sound, which signals that the program mode has been initiated. Programming for Rolling Door Locks: When the programming has been completed, a single tone from the chime system, will occur. Communication Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3525 The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25 and is white with a violet tracer. Additional tracer colors may be added to the violet in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on the RS/RG: - Body Control Module - Front Control Module - Occupant Restraint Controller - Occupant Classification Module - Controller Antilock Brake (MK20E) - Antilock Brake Module (MK25E) - Powertrain Control Module (Gas) - Transmission Control Module (Diesel Auto Only) - Engine Control Module (Diesel) - Radio - Amplifier - CD Changer - DVD/CD Changer - Hands Free Module - Automatic Temperature Control Module - A/C Heater Control Module (MTC) - Sentry Key Remote Entry Module (SKREEM) - Memory Seat/Mirror/Adjustable Pedals Module (MSMAPM) - Overhead Console - Mechanical Instrument Cluster - Left Sliding Door Control Module - Right Sliding Door Control Module - Thatcham Alarm Module (Export) - Power Liftgate Module - Park Assist Module Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRBIII(R) lab scope. The 12 v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open PCI circuit at the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: - All gauges on the MIC stay at zero - All telltales on MIC illuminate - MIC backlighting at full intensity - Dashed lines in the overhead console ambient temperature display - No response received from any module on the PCI bus (except the PCM/ECM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRBIII(R). Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected,suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRBIII(R) If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRBIII(R) may display BUS ± SIGNAL OPEN or NO RESPONSE to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRBIII(R) and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. NOTE: For 2005 model year, some vehicles will integrate the Transmission Control Module and Powertrain Control Module into a single control module. This new module is the Next Generation Controller for DaimlerChrysler and will be referred to as the Powertrain Control Module (PCM). The Transmission Control Module is part of the Powertrain Control Module. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3526 Diagnostic procedures and DTC numbers are some of the changes you will see which reflect the new combined module technology. The PCM will have four color coded connectors C1 through C4, (C1-BLK, C2-ORANGE, C3-WHITE, C4-GREEN), each PCM connector will have 38 pins each. Two new tools are used for probing and repairing the New PCM connectors. A New tool to release the pins from the PCM connectors Miller #3638 is introduced, you must use the Miller tool #3638 to release the connector pins or harness and connector damage will occur. Also a New tool for probing connectors Miller #8815 is introduced, you must use the Miller tool #8815 to probe the PCM pins or harness and connector damage will occur. There is also a new Verification test and module replacement procedure for the PCM. Door Ajar System The door ajar and liftgate ajar states are used as inputs for the Body Control Module (BCM). The BCM uses these inputs to determine exactly what position the doors and liftgate are in. The DRBIII(R) will display the state of the door ajar and the liftgate ajar switches in Inputs/Outputs. It's important to note, that when any door, or the liftgate is closed, the switch state on the DRBIII(R) will show OPEN. When any door, or the liftgate is open the switch state on the DRBIII(R) will show CLOSED. During diagnosis, if a door or the liftgate is closed and the DRBIII(R) displays the switch state as CLOSED, it indicates a shorted ajar circuit. If the door or the liftgate is open and the DRBIII(R) displays the switch state as OPEN, it indicates an open ajar circuit. Exterior Lighting System HEADLAMP POWER The Headlamp Switch is a direct input to the BCM. The BCM sends a BUS message to the FCM informing it of a headlamp switch status change. The FCM then turns on power to the headlamps through four fuseless circuits. These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied to each filament in a separate circuit. For vehicles equipped with daytime running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination. HEADLAMP SWITCH The Headlamp Switch uses a multiplexed (MUX) circuit to the Body Control Module (BCM). The Headlamp Switch controls the Fog lamp relay, Park lamps and the Low and High headlamps. The BCM then sends a signal through the PCI Bus line to the FCM as to what state the switch has selected. The FCM energizes the high side output drivers to turn ON the desired lamps. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3527 PARK LAMP RELAY The Park Lamp Switch is a direct input to the BCM. The BCM sends a BUS message to the FCM informing it to turn on the park lamp relay. The park lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. FOG LAMP RELAY The Fog Lamp switch is a direct input to the BCM. The BCM sends a BUS message to the FCM informing it to turn on the fog lamp relay. The fog lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Fog lamp functionality is not equipped on all vehicles. The FCM learns that the vehicle is equipped with fog lamps by reading the BCM BUS message. FOG LAMPS The BCM controls the operation of the fog lamp relay that turns the fog lamps ON and OFF. The Fog lamps can only be ON when the park and low beams are ON. If the high beams are switched ON then the Fog lamps will be automatically turned OFF. EXTERIOR LIGHTING BATTERY SAVER The BCM monitors the status of, and controls, the Park Lamps, Headlamps and Fog Lamp relays. If any exterior lamps are left ON after the ignition is turned OFF, the BCM will turn them OFF after 3 minutes. AUTO HEADLAMPS This feature is available on vehicles equipped with both the Electrocromatic Mirror (ECM) and the Compass/Mini-Trip Computer (CMTC). When the BCM detects a day/night signal from the CMTC, an ECM is present and Auto Headlamp mode is selected. Front Control Module The Front Control Module (FCM) is an electrical control and interface center located in the engine compartment. When it is mated to the Power Distribution Center (PDC), it is referred to as the Integrated Power Module (IPM). The IPM, with its fuses and relays provides power and signal distribution throughout most of the vehicle. The FCM receives both hard wire and digital electronic inputs from the vehicle electrical system through the PDC. Based on these inputs and the ignition switch position, it provides direct power feeds and relay control to some of the vehicles most critical electrical systems. The Front Control Module provides the following features: Controlled power feeds: - Front airbag system - Headlamp power - EATX module power (4 speed only) - Front washer motor - Rear washer motor - Cabin Heater - Brake shift interlock system Relay controls: - Fog lamp relay (when equipped) - Park lamp relay - Front wiper on relay - Front wiper high/low relay - Accessory relay - Horn relay - Front & rear blower relay - Name brand speakers (NBS) relay - Adjustable pedals relay (non-memory) - Electronic back light (EBL) run only relay Electrical inputs: - Headlamp battery supplies 1 & 2 - Module battery supply - Power ground - Ignition switch RUN or START position status - Ignition switch START only status - PCI Bus - Stop lamp switch - Horn switch - Back-up switch - Wiper park switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3528 - Washer fluid level switch - Brake fluid level switch - Ambient temperature sensor - Right park lamp outage - Left park lamp outage - Battery IOD - Battery (+) connection detection - Flash reprogramming voltage CONTROLLED POWER FEEDS Front airbag system The FCM provides power to the Occupant Restraint Control (ORC) system through two fuseless circuits (ORC RUN/START, and ORC RUN only). These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied while the ignition switch is in the RUN and START positions on pin 48 of the FCM connector, and in the RUN only position on pin 29. Headlamp power The headlamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a headlamp switch status change. The FCM then turns on power to the headlamps through four fuseless circuits. These circuits are electronically controlled and continuously monitored for malfunctions.Power is supplied to each filament in a separate circuit. For vehicles equipped with Daytime Running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination. EATX power The electronic automatic 4 speed transmission module is powered when the ignition switch is in the UNLOCK, RUN or START positions. This circuit is electronically controlled and continuously monitored for malfunctions. Power is supplied through pin 27 of the FCM connector. Front washer motor The front washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The front washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition, the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Rear washer motor The rear washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The rear washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition,the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Cabin Heater When the ignition is in Run, the FCM monitors the PCI bus for the Cabin Heater Activation request. The Automatic or Manual Temperature Control initiates this request only when all conditions for the Cabin Heater activation are favorable. The request carries the status bit that the FCM requires to activate its Cabin Heater Assist Control output. This output is a low side driver (coming from FCM pin 15) which supplies a ground signal to the Cabin Heater (pin 5). When the Cabin Heater receives this ground signal input, it interprets this as an activation signal. The FCM low side driver is also capable of diagnostic sensing. The driver will sense an open circuit when the driver is off, and will sense a short to voltage when the driver is on. The FCM will set DTC's for both of these types of faults. For additional information, refer to Cabin Heater under General Information and Diagnostic Procedures in the manual. Brake shift interlock system The brake shift interlock solenoid receives power from both high side and low side controls inside the FCM. The high side control is on the same circuit as the EATX module power, and the low side control comes through pin 47 of the FCM connector. The solenoid is controlled by the low side driver when the brake pedal is pressed. Both circuits are continuously monitored for malfunctions. RELAY CONTROLS Fog lamp relay The fog lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the fog lamp relay. The fog lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Fog lamp functionality is not equipped on all vehicles. The FCM learns that the vehicle is equipped with fog lamps by reading the BCM PCI Bus message. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3529 Park lamp relay The park lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the park lamp relay. The park lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper on relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper on relay. The front wiper on relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper high/low relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper high/ low relay. The relay switches power between the low speed and high speed windings of the wiper motor. The front wiper high/low relay is powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Accessory relay The accessory relay works in conjunction with the FCM's power accessory delay feature to control the operation of the radio, power windows, washer motors,wiper motors and power outlet. The accessory relay is turned on through low side control on pin 35 of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Depending on the ignition switch position, the accessory relay will remain on or will time-out and turn off. The accessory relay remains on in the RUN and ACCY positions of the ignition switch. In the UNLK and OFF positions, the relay will remain energized for 45 seconds then turn off. During this time-out period, if the driver or passenger doors are opened, the relay will turn off immediately. While the ignition switch is in the START position, the relay will also drop-out, then resume operation. Accessory relay operation is most noticeable by observing the operation of the radio or blower functions. Horn relay The horn relay operates through a direct wire input to the FCM from the horn switch (FCM pin 17) , or a PCI Bus message from the BCM. The relay responds to the horn switch, remote door lock and VTA alarm functions. The horn relay is powered through low side control on pin 10 of the FCM. Under normal operating conditions, if the horn is pressed for longer than 30 seconds, the FCM will automatically deactivate the horn to prevent damage to it. The FCM will re-activate control of the relay after a 25 second cool-down period. This circuit is electronically controlled and continuously monitored for malfunctions. Front and rear blower relay RS with MTC Upon ignition on, the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus.The front blower relay and the rear blower relay, if equipped, are then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. RG with MTC Upon power up (Power switch on), the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus. The front blower relay is then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. Name Brand Speakers (NBS) relay The NBS relay operates through the vehicle bus interface between the radio and the FCM. When the radio is turned on, the radio sends a PCI Bus message to the FCM. The NBS relay is then powered on through low side control on pin 11 of the FCM. The relay supplies power to the amplified speaker, and ground is supplied through the radio. This circuit is electronically controlled and continuously monitored for malfunctions. Electronic Back Light (EBL) relay The rear defrost switch is part of the Automatic Temperature Control or A/C-Heater Control Module (Manual Temp). When the ignition switch is in the RUN position and the rear defrost switch is turned on, the ATC or A/C-Heater Control Module sends a PCI Bus message to the FCM. The EBL run only relay is then powered through low side control on pin 31 of the FCM. The relay provides the high side to the rear window defrost grid, and ground is attached to the vehicle body. The FCM will only allow the rear defrost to operate in the RUN position. This circuit is electronically controlled and continuously monitored for malfunctions. Adjustable Pedals Relay (Non-Memory) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3530 The Adjustable Pedals Relay is only on nonmemory Adjustable Pedals System equipped vehicles. The relay is supplied battery voltage from the IPM and is electronically controlled with a low side driver within the FCM. The relay is energized when the transmission is in reverse and when cruise control operation is engaged. This action disables the Adjustable Pedals System from movement. This circuit is continuously monitored for proper function. ELECTRICAL INPUTS Headlamp battery supplies 1 & 2 - 12 volt input on pins 1 and 2. Battery supply voltage for switching headlamp circuits only. Module battery supply - 12 volt input on pin 9. Battery supply voltage for all other FCM operations. Power ground - Ground source on pin 8 for all FCM operations. Ignition switch RUN or START position status - 12 volt input on pin 37. Allows the FCM to determine the ignition switch status for related FCM operations. PCI Bus - Approximately 7.5 volt input on pin 22. Allows the FCM to communicate with other modules on the vehicle bus. Stop lamp Switch status - 12 volt input on pin 44. Provides for brake shift interlock function. Horn Switch - Ground input on pin 17. Primary means for engaging the horn. Back-up switch - Ground input on pin 39. Input is converted to a PCI Bus status message for use by other modules. Wiper park switch - Ground input on pin 16. Used to determine park placement of wipers. Also used as feedback to FCM to determine correct operating mode of wipers. Washer fluid level switch - Ground input to pull-up on pin 18. Ground is switched into the circuit when washer bottle fluid level is low. Brake fluid level switch - Ground input to pull-up on pin 36. Ground is switched into the circuit when brake fluid level is low. Ambient temperature sensor - Resistive input to pull-up on pin 25. Corresponding voltage level is converted to a PCI Bus message for use by other modules on the bus. Right park lamp outage - 12 volt input on pin 21. Used to determine if right park lamp circuit is operating properly. Left park lamp outage - 12 volt input on pin 41. Used to determine if left park lamp circuit is operating properly. Battery IOD - 12 volt input on pin 20. The FCM enters a low power consumption mode when the ignition is turned OFF. This low current draw battery supply keeps the microprocessor functioning in the low power mode. Battery (+) connection detection - 12 volt input on pin 38. The battery connection on the PDC incorporates the use of an internal switch to determine if the connector is properly mated and the Connector Positive Assurance (CPA) is engaged. If the CPA is not properly engaged, a voltage on pin 38 will be interpreted as an unseated connector and a fault will set. Flash programming voltage - 20 volt input on pin 42. When a DRBIII(R) is connected and the proper flash reprogramming sequence is selected, the 20 volt signal will be applied through pin 42. Heating and A/C System AUTOMATIC TEMPERATURE CONTROL (ATC) MODULE USAGE CAUTION: Do not swap ATC Modules from vehicle to vehicle. Software versions differ between models and between model years. Installing a ATC Module with software that is incompatible for a given vehicle can result in either improper or failed HVAC system operation. SYSTEM AVAILABILITY - The ATC system is a Three-Zone Air Conditioning System. SYSTEM CONTROLS The ATC Module: - is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - provides an A/C request over the PCI Bus to the Powertrain Control Module (PCM) when compressor operation is desired. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3531 - for exports with diesel engines, provides a Cabin Heater activation request over the PCI Bus to the Front Control Module (FCM) when conditions are favorable for Cabin Heater operation. - uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - uses input from infrared (I/R) sensors, which measure surface temperature, to maintain occupant comfort levels. The I/R sensors are mounted in the instrument panel center bezel. - can be operated in a manual mode. - provides a blower relay on request over the PCI Bus to the Front Control Module (FCM) when blower operation is desired. - controls front blower operating speed, providing 10 speeds in manual mode and infinite speeds in automatic mode. - provides a cold engine blower lockout function. A Blower Speed Clamping feature minimizes occupant discomfort by controlling the amount of warm air coming out of the HVAC system should the Powertrain Control Module (PCM) disable A/C Compressor operation while the Automatic Temperature Control (ATC) is set in an automatic mode. The PCM disables the A/C compressor if the A/C pressure is too low, if the A/C pressure is too high, if engine overheating is immanent, or if an engine overheating condition exists. The ATC clamps the blower speed if the outside air temperature is greater than 50° F (10° C) and the PCM has disabled the A/C compressor. This means that the ATC will not adjust blower speed automatically when the clamping feature is enabled, e.g. if the clamping feature is enabled while in Auto Lo the blower will continue to run in low speed; if the clamping feature is enabled while in Auto Lo and the operator selects Auto Hi the blower will continue to run in low speed; if the clamping feature is enabled while in Auto Hi the blower will continue to run at the highest speed. In any case the operator can manually change the blower speed as desired. When diagnosing blower related symptoms verify that none of the above conditions for disabling the A/C compressor exist before diagnosing the blower circuits and components. - controls rear blower operating speed, providing 10 speeds in manual mode and infinite speeds in automatic mode. The separate front and rear Blower Motor Controllers operate as follows: When blower operation is desired, the Blower Motor Controller provides a 10.0 volt signal to the ATC Module over a control circuit. The ATC Module provides a variable duty cycle ground to the 10.0 volt signal based on input from the blower switch. When the blower switch is set to LO speed, the ATC Module provides a short duty cycle (less time grounding the signal voltage). As higher blower speeds are requested, the ATC Module increases the duty cycle (more time grounding the signal voltage). When the blower switch reaches HI speed, the duty cycle increases to where the signal pattern is almost a flat line (with brief voltage spikes). - controls the front and rear electric door actuators operation. A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The ATC Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the ATC Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. - activates and deactivates the Rear ATC Switch. The Rear ATC Switch (Three-Zone Only): - provides desired rear blower speed input to the ATC Module. - provides desired rear blend and mode door position input to the ATC Module. The Dual-Zone ATC system uses: - two front, two-wire electric blend door actuators. - one front, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. The Three-Zone ATC system uses: - two front, two-wire electric blend door actuators. - one front, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. - one rear, two-wire electric blend door actuator. - one rear, two-wire electric mode door actuator. System Relays: - The Integrated Power Module (IPM) houses and provides power to the A/C Clutch Relay, Front Blower Motor Relay, and Rear Blower Motor Relay. SYSTEM REVISIONS The 2005 ATC system remains mostly carryover from 2004. Revisions to the 2005 ATC system include: - all new version 0012 software. SYSTEM DIAGNOSTICS Fault detection is through active and stored Diagnostic Trouble Codes (DTC's) - DTC's are displayed the DRBIII(R). - Active DTC's are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTC's are those which occurred in the system since the ATC Module received the last "clear diagnostic info" message. The AC Cooldown Test: - is actuated with the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3532 - checks A/C system performance based on evaporator temperature sensor input. WARNING: DO NOT OPERATE THE DCHA IN AN ENCLOSED AREA SUCH AS A GARAGE THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS VENT THE DCHA's EXHAUST WHEN OPERATING THE DCHA. REFER TO VENTING THE DCHA's EXHAUST UNDER CABIN HEATER IN THE GENERAL INFORMATION PORTION OF THIS SECTION FOR PROPER EXHAUST VENTING INSTRUCTIONS. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. CAUTION: Do not activate the A/C Cooldown Test with the engine off. Failure to follow these instructions can result in internal damage to the DCHA Heater Module. - The FCM monitors the PCI bus for the Cabin Heater Activation request. The request carries the status bit that the FCM requires to activate it's Cabin Heater Assist Control output. This output is a low side driver (coming from FCM pin 15) which supplies a ground signal to the Cabin Heater (pin 5). When the Cabin Heater receives this ground signal input, it interprets this as an activation signal. - The FCM low side driver is also capable of diagnostic sensing. The driver will sense an open circuit when the driver is off, and will sense a short to voltage when the driver is on. The FCM will set DTC's for both of these types of faults. For additional information, refer to Cabin Heater under General Information and Diagnostic Procedures. - will not run the air conditioning portion of this test if ambient temperature is below 12° C (53° F). The forced Cabin Heater activation will occur even if the air conditioning portion of this test fails to initiate because AC Cooldown test criteria was not met. When activated, the DCHA will operate for approximately seven minutes. Three minutes to run and four minutes to purge. - will pass the air conditioning portion of this test if the evaporator temperature drops 6.7° C (20° F) within two minutes of starting this test. - messages (air conditioning related only) display on the DRBIII(R) after running this test. These messages will clear after paging back out of this test. Therefore, it is important to note all of the AC Cooldown test messages before doing so. - All Cabin Heater-related DTC's display under Cabin Heater, Read DTC's. - will cause the DELAY and Snowflake VF segments on the ATC to flash for 162 seconds (RG with DCHA only). If the air conditioning portion of this test fails, the DELAY and Snowflake VF segments will continue to flash until the vehicle is driven more than three miles. MANUAL TEMPERATURE CONTROL (MTC) Vehicle Compatibility For MTC Modules MODULE USAGE SYSTEM AVAILABILITY - Three different types of systems are currently available for these vehicles. Single-Zone Air Conditioning System - Dual-Zone Air Conditioning System - Three-Zone Air Conditioning System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3533 SYSTEM CONTROLS The A/C-Heater Control Module: - is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - provides an A/C request to the Powertrain Control Module (PCM) over the PCI Bus when compressor operation is desired. - uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - for exports with diesel engines, provides a Cabin Heater activation request to the Front Control Module (FCM) over the PCI Bus when conditions are favorable for Cabin Heater operation. - for RS vehicles, provides a blower relay on request to the FCM over the PCI Bus upon ignition on. - for RG vehicles, provides a blower relay on request to the FCM over the PCI Bus when the Power switch on the A/C-Heater Control Module is turned on. - controls front blower operating speed. For RS vehicles, the four speed settings are Low, M1, M2, and High. For RG vehicles the five speed settings are Low, M1, M2, M3, and High. - for RS vehicles uses the blower switch to control system on/off and blower speed. - for RS vehicles uses the rear wiper/washer switch to control rear wiper/washer operation. - for RS vehicles, provides a rear wiper on request to the Body Control Module (BCM) when rear wiper operation is desired. - for RS vehicles, provides a rear washer on request to the Body Control Module (BCM) when rear washer operation is desired. - controls EBL operation. - on three-zone systems, activates and deactivates the Rear A/C-Heater Control. - on three-zone systems, controls rear blower operating speed. The three speed settings are Low, Med, and High. - controls the front and the three-zone system rear electric door actuators operation. A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C - Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. On Three-Zone systems, the Rear A/C-Heater Control: - controls rear blower motor operating speed. The three blower speeds are Low, Med, and High. - provides desired rear blend and mode door position input to the A/C-Heater Control Module. The Single-Zone HVAC system uses: - one, two-wire electric blend door actuator. - one, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. The Dual-Zone HVAC system uses: - two, two-wire electric blend door actuators. - one, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. The Three-Zone HVAC system uses: - two front, two-wire electric blend door actuators. - one front, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. - one rear, two-wire electric blend door actuator. - one rear, two-wire electric mode door actuator. System Relays: - The Integrated Power Module (IPM) houses and provides power to the A/C Clutch Relay, Front Blower Motor Relay, and Rear Blower Motor Relay. SYSTEM REVISIONS The 2005 MTC system remains mostly carryover from 2004. Revisions to the 2005 MTC system include: SYSTEM DIAGNOSTICS Fault detection is through active and stored Diagnostic Trouble Codes (DTC's) - DTC's are displayed by the DRBIII(R). - Active DTC's are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTC's are those which occurred in the system since the A/C-Heater Control Module received the last "clear diagnostic info" message. The A/C Cooldown Test: - is actuated with the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3534 - checks A/C system performance based on evaporator temperature sensor input. - will not run if ambient temperature is below 12.7° C (55° F). - will pass if the evaporator temperature drops 6.7° C (20° F) within two minutes of starting the test. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - for RS vehicles will cause the Rear Wipe/Wash and A/C status indicators on the A/C-Heater Control Module to flash alternately while the test is running. - for RG vehicles will cause the PWR and A/C status indicators on the A/C - Heater Control Module to flash alternately while the test is running. The A/C status indicator will flash twice per second to indicate that the A/C Cooldown Test needs to be run. The A/C status indicator will stop flashing twice per second if either the A/C Cooldown Test returns passed, or if any button on the control is pressed, or if the ignition is cycled and the odometer shows greater than eight miles. The HVAC Door Recalibration function: - is actuated with the DRBIII(R) After completing HVAC Door Recalibration, the DRBIII(R) will the store the total span and the status of each door actuator. Selecting HVAC Door Cal Monitor in the System Tests will display this information. - homes and repositions door actuators. - monitors for door span faults on the actuator circuits. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - for RS vehicles will cause the Rear Wipe/Wash and RECIRC status indicators on the A/C-Heater Control Module to flash alternately while the test is running. - for RG vehicles will cause the PWR and RECIRC status indicators on the A/C - Heater Control Module to flash alternately while the test is running. The RECIRC status indicator will flash twice per second to indicate that the HVAC Door Recalibration Test needs to be run. The RECIRC status indicator will stop flashing twice per second if either the HVAC Door Recalibration Test returns passed, or if any button on the control is pressed, or if the ignition is cycled and the odometer shows greater than eight miles. The Actuator Circuit Test: - is actuated with the DRBIII(R). - monitors for shorted actuator circuits. - allows service to easily diagnose and troubleshoot up to three simultaneous shorts. - supplements the continuous diagnostics on the actuator drive system. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. When Performing the Actuator Circuit Test CAUTION: - Shorted rear door driver circuits can cause additional Actuator Circuit Test messages to set for circuits where no condition exists to cause a fault. - To ensure a proper diagnosis, repair all Short Too Complex messages first, all rear door driver circuit related messages second, all common door driver circuit related messages third, and all front door driver circuit related messages last. - The DRBIII(R) can display up to three Actuator Circuit Test messages at a time. After repairing each Actuator Circuit Test message, cycle the ignition switch, then rerun the Actuator Circuit Test to ensure no new messages exist. - The Short Too Complex message: indicates that a specific determination of which lines are shorted could not be made. - is caused by more than three drivers being shorted in the same direction. For example, four drivers all shorted to ground, or two or more drivers shorted with at least one driver shorted to ignition/battery and one driver shorted to ground. - Messages displaying: XXX Driver/Circuit Shorted to Ignition/ Battery will set on a per-driver basis. - XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. - the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together.When the test returns passed, then troubleshooting should proceed to clearing faults and running the HVAC Door Recalibration system test as a final check of system health. Instrument Cluster The Instrument Cluster receives and sends messages to other modules via the PCI bus circuit. The indicator lamps will illuminate briefly for a bulb check when the ignition is turned from off to run. All of the gauges receive their information via the PCI bus from the powertrain control module and body control module. The gauges and the LEDs are not individually replaceable thereby requiring complete replacement of the Instrument Cluster if a repair is necessary. In the event that the Instrument Cluster loses communication with other modules on the PCI bus, the cluster will display no bus in the VF display. The Trip/Reset button is used to switch the display from trip to total mileage. Holding the button when the display is in the trip mode will reset the trip Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3535 mileage. This button is also used to put the cluster into self-diagnostic mode. The odometer display uses blue-green vacuum fluorescent digital characters. On base models, the Instrument Cluster has three gauges: Speedometer, fuel and temperature.A red dot appears through openings in the Instrument Cluster face (P-R-N-D-2-1) to indicate the gear selected. With other models, the Instrument Cluster may also include a tachometer and use a vacuum fluorescent shift indicator. The high-line Instrument Cluster features Electroluminescent Illumination of the gauge faces (EL Panel). This feature eliminates the use of bulbs for ,gauge/panel lighting. In a manner similar to fluorescent lights, a/c voltage from an inverter integrated circuit chip is applied to the phosphorescent material, causing it to glow. The phosphorescent material is screen-printed onto flexible Mylar sheets that form the gauge faces. The odometer display and door/liftgate ajar indicators turn on when a door is opened to assist both the customer and service technician to view the odometer without turning the ignition on. On models with AutoStick, the display includes an O/D OFF indicator that is illuminated when the driver presses the Overdrive Off button on the transaxle shifter. INSTRUMENT CLUSTER SELF TEST 1. Depress and hold the Odometer Reset button. 2. Turn the ignition switch to on. 3. Release the Odometer reset button. The Instrument Cluster will illuminate all indicators and step the gauges through several calibration points.Also, the odometer will display any stored codes that may have set. Interior Lighting COURTESY LAMP CONTROL The body controller has direct control over all of the vehicle's courtesy lamps. The body computer will illuminate the courtesy lamps under any of the following conditions: 1. Any door ajar and courtesy lamp switch on the headlamp switch is not in the dome off position. 2. The courtesy lamp switch on the headlamp switch is in the dome on position. 3. A Remote Keyless Entry unlock message is received. 4. Driver door unlocked with key (with VTSS only). ILLUMINATED ENTRY Illuminated entry will be initiated when the customer enters the vehicle by unlocking the doors with the key fob, or with the key if the vehicle is equipped with vehicle theft alarm. Upon exiting the vehicle, if the lock button is pressed with a door open, illuminated entry will cancel when the door closes. If the doors are closed and the ignition switch is turned on, the illuminated entry also cancels. The illuminated entry feature will not operate if the courtesy lamp switch is in the dome off position. INTERIOR LIGHTING BATTERY SAVER If any of the interior lamps are left on after the ignition is turned off, the BCM will turn them off after 8 minutes. To return to normal operation, the courtesy lamps will operate after the dome lamp switch or door ajar switch changes state. The glove box and switched reading lamps require that the ignition be turned to the on/acc position. Memory System The memory system consists of power driver's seat, power mirror, adjustable pedals and radio presets. The Memory Seat/Mirror/Adjustable Pedals Module (MSMAPM) is located under the driver's seat. It receives input from the following: driver's manual 8-way seat switch, driver's seat position sensors, PCI bus circuits, and the power mirror sensors. The module uses these inputs to perform the following functions: position the driver's memory seat, both exterior mirrors (during recalls), both pedals, and send/receive the memory system information over the PCI bus. The Memory Set Switch is wired to the Body Control Module (BCM). A button (either #1 or #2) pressed on the set switch causes the BCM to send a message to the MSMAPM which in turn will send a motion status message back to the BCM. If the message from the MSMAPM indicates no current motion, the BCM will send a recal message to the module. The MSMAPM will set the seat, exterior mirror, pedals, and radio to the presets for the indicated driver. If any one of the memory controlled systems is inoperative from its manual switch, use the schematics and diagnostic information to correct the concern. This manual addresses the memory problems only and it is assumed there is not a basic component failure. POWER SEAT The memory power seat provides the driver with 2 position settings for the driver's seat. Each power seat motor is connected to the MSMAPM with two motor drive circuits. Each circuit is switched between battery and ground. By being able to bidirectionally drive the circuits, the MSMAPM controls the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3536 movement of the motors based on input from the power seat switch or from the position sensors when performing a memory recall. Each motor contains a potentiometer to monitor the seat position. To monitor the position of the motor, the MSMAPM sends out a 5-volt reference on the sensor supply circuit.The sensor is grounded back to the module on a common ground circuit. Based on the position of the sensor, the MSMAPM monitors the voltage change through the sensor on a separate signal circuit. The MSMAPM stores the input value of each of the four seat potentiometers in memory when the system requests a set. The driver can initiate a memory recall, using either the door mounted memory switch or the RKE transmitter (if the remote linked to memory feature is enabled via the EVIC). When initiated, the MSMAPM adjusts the four seat sensors (by using the motors) to match the memorized seat position data. For safety, the memory seat recall is disabled by the MSMAPM when the vehicle is out of park position or if the speed is not zero. Any obstruction to seat movement over a 2-second delay will cause the seat to stop moving in which case a stalled motor would be detected by the MSMAPM and the corresponding seat output would be deactivated. However, if the object obstructing the seat is removed, the seat will function normally again. MEMORY MIRROR The driver side view mirror contains vertical and horizontal bi-directional drive positioning motors and position sensors. The MSMAPM provides a 5-volt reference on the signal circuit to each position sensor. The sensors share a common ground circuit. The MSMAPM monitors the position of the mirror motors by measuring the voltage on each signal circuit. When a memory position is set, the MSMAPM monitors and stores the position of the outside mirror. The MSMAPM adjusts the mirror to the appropriate positions when a memory recall message is received from the RKE or is requested from the memory set switch. The power mirror switch during non-memory operation operates the mirror independently of the MSMAPM. Overhead Console COMPASS/TEMPERATURE MODULE, COMPASS/MINI-TRIP COMPUTER or ELECTRONIC VEHICLE INFORMATION CENTER The Compass/Temperature Module (CT), Compass/Mini-Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) is located in the overhead console. The CT provides the vehicle operator with only outdoor temperature and the compass heading. The CMTC or EVIC supplements the standard vehicle instrumentation. The CMTC and EVIC use a vacuum fluorescent (VF) display to supply the vehicle operator with a compass heading, outdoor temperature, average fuel economy, distance to empty, trip odometer, elapsed ignition on time, distance to service, warning messages, and service messages. The difference between a CMTC and an EVIC is that only the EVIC provides additional memory, feature programming, and warning messages. The EVIC is capable of displaying warning messages and memory system messages when the vehicle is equipped with memory systems. The EVIC also provides the interface to enable and disable vehicle programmable features when the vehicle is equipped with certain features. If equipped, the EVIC is also available with an integrated Universal Garage Door Opener (UGDO) known as HomeLink(R). The EVIC may also be equipped with up to 4 power door switches: ON/ OFF, Left Sliding Door, Right Sliding Door, and Liftgate. The CT function buttons are labeled C/T and US/M. The CMTC function buttons are labeled US/M, C/T, RESET, and STEP. The EVIC function buttons are labeled C/T, RESET, STEP, and MENU. The three UGDO buttons are labeled with dots to indicate the channel number. The BCM supplies most of the information displayed by the CMTC/EVIC. Display information, except for the internal compass function, is received over the PCI bus. The FCM supplies the ambient temperature sensor information via the PCI bus. The CMTC/EVIC sends and receives data over the PCI bus, communicating with the BCM, PCM, FCM, and the Instrument Cluster. Tire Pressure Monitoring System information is received from the SKREEM via PCI bus information. The tire pressure sensors are mounted to the vehicle wheels. For complete information, refer to the Tire Pressure Monitoring System section. VEHICLE INFORMATION DISPLAY The CMTC/EVIC provides the following functions: - Compass direction - Outside temperature - Elapsed ignition on time - Distance to empty - Average fuel economy - Trip odometer - Distance to service The EVIC will also display the following driver alert messages: - TURN SIGNAL ON (with vehicle graphic) - PERFORM SERVICE - DOOR OPEN (individual or multiple doors, with graphic) - LOW TIRE PRESSURE (when equipped) - ADJUSTABLE PEDAL DISABLED CRUISE ENGAGED (when equipped) - ADJUSTABLE PEDAL DISABLED VEHICLE IN REVERSE (when equipped) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3537 An audible chime or chimes will accompany any displayed warning messages. Chime requests with an OPEN message are dependent upon vehicle speed. The CT/CMTC/EVIC will not display information for any of the screens for which it did not receive the proper PCI bus data. Refer to the symptom list in the Overhead Console section for problems related to the CT/CMTC/EVIC. The CMTC/EVIC receives the following messages from the Body Control Module (BCM): - Verification of US/Metric status - VF display dimming brightness and exterior lamp status - Elapsed Ignition On Time data - Average Fuel Economy - Distance to Empty - Distance to service - Driver warning messages The CT/CMTC/EVIC receives the following messages from the Front Control Module (FCM): - Outside Temperature The CMTC/EVIC receives the following messages from the Powertrain Control Module (PCM): - Trip Odometer data - Vehicle Speed The EVIC receives the following messages from the Adjustable Pedal System Module (APS): - APS status warnings The CT/CMTC/EVIC receives the following messages from the Sentry Key Remote Electronic Entry Module (SKREEM): - Tire Pressure information The CMTC/EVIC transmits the following messages to the BCM: - Status Request: Beep, Reset, US/M Toggle - Current Display STEP BUTTON The STEP Button can be used in one of the following three ways: 1. To sequentially select one of seven displays or blank display in the following order: - Average Fuel Economy - Distance to Empty - Trip Odometer - Time Elapsed - Distance to Service Message - Off (Blank) 2. To set the magnetic variance zone when VARIANCE = X (X = 1 - 15) is indicated in the VF Display. 3. To select the displayed programmable feature setting. (When equipped.) MENU BUTTON (EVIC only) For complete information of the programmable features and memory messages. Use the MENU button to sequentially step the EVIC through the programmable features. MENU BUTTON (EVIC only) For complete information of the programmable features and memory messages.Use the MENU button to sequentially step the EVIC through the programmable features. RESET BUTTON The RESET Button has two different functions: 1. To clear the trip functions that may be reset 2. To enter and exit the diagnostic mode Pressing the RESET button once will clear the trip function that is currently being displayed (except Distance to Service) and the CMTC/EVIC will send a PCI bus beep request to the BCM. If the RESET button is pressed again within 3 seconds, the CMTC/EVIC will reset ALL of the trip functions and an additional beep request is sent to the BCM. The trip functions that may be reset are: - Average Fuel Economy - Trip Odometer - Elapsed Time Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3538 A reset will only occur if one of the trip functions that may be reset is currently being displayed. Pressing the RESET button for more than three (3) seconds resets the Distance to Service function while the Distance to Service message is being displayed. The CMTC/EVIC module will send a beep request to the BCM. Simultaneously pressing the RESET button and the STEP button while turning the ignition from Off to On will enter the CMTC/EVIC into the self-diagnostic mode. COMPASS/TEMPERATURE (C/T) BUTTON Actuating the Compass/Temperature Button (C/T) will cause the CMTC/EVIC to display the compass and temperature information. This function will operate from another traveler display or from the programmable feature mode. TRAVELER DISPLAY FUNCTIONS Using the STEP button will change the CMTC/ EVIC between modes of operation and display the appropriate information according to data received from the PCI Bus. COMPASS/TEMPERATURE The CMTC/EVIC simultaneously displays the compass reading and the outside temperature. Outside temperature information is received via the PCI bus from the FCM. The CMTC/EVIC module internally senses and calculates the compass direction. COMPASS OPERATION - ALL Upon ignition on, if the calibration information stored in the CMTC memory is within the normal range, the CMTC will perform in slow Auto-Cal mode. In slow Auto-Cal mode, the CMTC continuously compensates for the slowly changing magnetic field of the vehicle. The compass module detects changes in the vehicle magnetism and makes appropriate internal corrections to ensure proper displayed direction. However, if the calibration information stored in the CMTC memory is not within the normal range at ignition on, the CMTC will enter fast Auto-Cal. CAL is displayed along with the temperature. Auto activation of the fast Auto-Cal mode will also occur when the CMTC is subjected to high magnetic field strength levels, which cause all compass readings to be erroneous for a continuous period of five (5) minutes. During fast Auto-Cal, CAL will be displayed along with the temperature. Fast Auto-Cal can also be performed manually, by pressing and holding the RESET button for 10 seconds during the Compass/Temperature display mode. SETTING MAGNETIC ZONE VARIANCE Variance is the difference between magnetic North and geographic North. For proper compass function, the correct variance zone must be set. Refer to the Zone Variance map for the correct zone. Follow these steps to check or change the variance zone: CMTC/EVIC: - The ignition switch must be in the On position and the CMTC/EVIC display must not be blank. - If the compass/temperature data is not currently being displayed, momentarily press and release the C/T button to display compass/temp information. - Press and hold the RESET button (approximately 5 seconds) until VARIANCE = XX is displayed. The CMTC/EVIC will display the variance zone stored in memory and the word VARIANCE. - Use the RESET button to select the proper variance zone number, 1 through 15. - After selecting the proper zone number, momentarily press and release the RESET button. The variance zone is then stored in the memory and the CMTC/EVIC returns to normal operation. CT: - The ignition switch must be in the On position and the C/T display must not be blank. Press and hold the C/T and US/M buttons (approximately 5 seconds) until VARIANCE = XX is displayed. The C/T will display the variance zone stored in memory and the word VARIANCE. - Use the US/M button to select the proper variance zone number, 1 through 15. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3539 - After selecting the proper zone number, momentarily press and release the C/T button. The variance zone is then stored in the memory and the C/T returns to normal operation. COMPASS CALIBRATION The compass module has 2 types of auto calibration; slow-cal and fast-cal. Slow-cal ensures that during normal vehicle operation th0e compass performs auto-calibration functions to keep the compass sensors in their proper operating range. Whenever the ignition is On and the CT/CMTC/ EVIC receives PCI bus data indicating that engine RPM is greater than zero, auto-calibration is performed continuously. If the calibration information stored in the compass module memory is not within the normal range after a power-up cycle, the compass will display CAL. The CT/CMTC/EVIC will enter into the fast-cal mode until calibration is complete. To enter the compass into Manual Calibration mode, perform the following steps: - Drive the vehicle to an area away from any large metal objects or overhead power lines. - Ensure that the proper variance zone is selected. See "Setting Magnetic Zone Variance". - The ignition switch must be in the On position and the CMTC/EVIC display must not be blank. - Press the C/T button to view the Compass/ Temperature display. - Press and hold the RESET button (approximately 10 seconds) until CAL is displayed, then release the button. - Drive slowly, less than 5 MPH (8 KPH) in at least 1 complete 360-degree circle. - CAL will remain illuminated to alert the driver that the compass is in the calibration mode. - After calibration is complete, CAL will turn off. NOTE: For C/T Manual Calibration, perform the same procedure as above, but press and hold the C/T and US/M buttons until CAL is displayed. If the compass appears blank, unable to be calibrated, or the compass displays false indications,the vehicle must be demagnetized. SELF-CHECK DIAGNOSTICS The CT/CMTC/EVIC is capable of performing a diagnostic self check on its internal functions. Diagnostics may be performed using a DRBIII(R) or by using the following procedure: 1. For CMTC/EVIC: With the ignition switch in the OFF position, depress and hold the RESET and the STEP buttons. For CT: With the ignition switch in the OFF position, depress and hold the C/T and the US/M buttons. 2. Turn the ignition switch to the ON position. 3. Continue to hold both buttons until the software versions are displayed, then release the buttons. 4. All of the VFD segments will illuminate for 2-4 seconds. Check for segments that do not illuminate or illuminate all the time. 5. When the self-check is complete the EVIC will display one of the following messages: - PASS SELF TEST - FAILED SELF TEST - NOT RECEIVING J1850 MESSAGE When the self-check is complete the CT/CMTC will display one of the following messages: - PASS - FAIL - BUS 1. To exit the self-check mode: For the CMTC/EVIC: Depress the STEP or RESET button, or cycle the ignition switch and the CMTC/EVIC will return to normal operation. For the C/T: Depress the C/T or US/M button, or cycle the ignition switch and the CT will return to normal operation. If a Communication fault is displayed, refer to the symptom list. If a FAIL or FAILED is displayed, the CT/CMTC/EVIC must be replaced. AMBIENT TEMPERATURE SENSOR Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3540 The ambient air temperature is monitored by the FCM and displayed by the CT/CMTC/EVIC. The FCM receives a hardwire input from the ambient temperature sensor (ATS). The ATS is a variable resistor that operates on a 5-volt reference signal circuit hardwired from the FCM. The resistance in the ATS changes as the outside temperature rises or falls. The FCM senses the change in reference voltage through the ATS resistor. Based on the resistance of the ATS, the FCM is programmed to correspond to a specific temperature. The FCM stores and filters the ambient temperature data and transmits this data to the CMTC/EVIC via the PCI Bus. The ATS cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. AMBIENT TEMPERATURE SENSOR FAULT CODES The outside temperature function is supported by the ambient temperature sensor (ATS), a signal and ground circuit hardwired to the FCM, and the CMTC/EVIC display. If the ATS sense circuit is shorted to ground, the temp display will be 54° C (130° F) to indicate SHORT circuit condition. If the ATS sense circuit is open, the temp display will be -40° C (-40° F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the CMTC/EVIC VFD can be tested. The ATS is supported by the FCM. Ambient Temperature Sensor DTC's will be recorded in the FCM. The ATS can be diagnosed using the following Sensor Test. Test the ATS circuits using the diagnostics in the Body Diagnostic Procedures Manual. If the CMTC/EVIC passes the self-test, and the ATS, the circuits, and PCI bus communications are confirmed to be OK, but the CMTC/EVIC temperature display is inoperative or incorrect, replace the FCM. AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: - 0° C (32° F) Sensor Resistance = 29.33 - 35.99 Kilohms - 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kilohms - 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kilohms - 25° C (77° F) Sensor Resistance = 9.12 - 10.86 Kilohms 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kilohms - 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance values are not OK, replace the Sensor. HOMELINK(R) UNIVERSAL TRANSMITTER If equipped, HomeLink(R) Universal Transmitter is integrated into the overhead console. For added security it will operate home security systems that use coded signals known generically as Rolling Codes. The overhead console display provides visual feedback to the driver, indicating which HomeLink(R) transmitter channel button is being pressed. The HomeLink(R) can learn and store up to three separate transmitter radio frequency codes to operate garage door openers, security gates, and security lighting. The HomeLink(R) buttons are marked with one, two, or three dots. For complete information. TIRE PRESSURE MONITORING SYSTEM (TPMS) If equipped with the Tire Pressure Monitoring System (TPMS), each of the vehicles four wheels will have a valve stem with a pressure sensor and radio transmitter built in. Signals from the tire pressure Sensor/Transmitter are received and interpreted by the Sentry Key Remote Entry Module (SKREEM). Using the DRBIII(R), go to ANTI-THEFT for the SKREEM data. A Sensor/Transmitter in a mounted wheel will broadcast an RF frequency indicating its pressure once per minute when the vehicle is in drive mode. To activate the Sensor/Transmitter operation, the required SKREEM speed is 13 mph (20 km/h). Each Sensor/Transmitters broadcast is uniquely coded so that the SKREEM can monitor the states of each Sensor/Transmitter on the vehicle. The SKREEM TPMS does not use a magnet to relearn, it automatically learns while driving after a SKREEM or a Sensor/Transmitter has been replaced. TRAINING THE SKREEM If a Sensor/Transmitter is replaced, the vehicle has to be parked for at least 15 minutes for the system to be ready to learn the new Sensor/Transmitter ID code. The vehicle then must be driven for a minimum of five minutes with a minimum continuous speed above 13 mph (20 km/h). The system will learn the new Sensor/Transmitter and clear the DTC's automatically. The Sensor/ Transmitters are programmed at the assembly plant in this clockwise orientation: Sensor/Transmitter 1 = Left Front Sensor/Transmitter 2 = Right Front Sensor/Transmitter 3 = Right Rear Sensor/Transmitter 4 = Left Rear NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3541 1. If one or all Sensor/Transmitters cannot be trained, check for and avoid RF interference. 2. If one Sensor/Transmitter still cannot be trained, replace it and retry. 3. If all Sensor/Transmitters still fail to train, replace the SKREEM. PRESSURE THRESHOLDS The SKREEM will monitor the tire pressure signals from the Sensor/Transmitters and determine if any tire has gone below the low-pressure or above the high-pressure thresholds. Refer to the tables below: Low Tire Pressure Thresholds High Tire Pressure Thresholds *Tolerance ±6.9 kPa (1 PSI) ACTIVE FAULT AND SYSTEM ALERTS An active fault will be triggered when a system failure has been detected. When this occurs, the Instrument Cluster will illuminate the TPMS indicator and the SKREEM will store the fault code. An alert will be triggered when a tire pressure has gone below or above the set threshold pressure. When this occurs, the Instrument Cluster will flash the TPMS indicator. The SKREEM will request a secondary message to be displayed on the EVIC (if equipped). Only when a tire pressure has gone below the set threshold pressure will the SKREEM request the TPMS indicator to flash and display the EVIC message (if equipped). When a high pressure alert occurs, only the EVIC message will be displayed. This action will be displayed as long as the alert condition is active. Park Assist System The Park Assist System display activates an audible tone that changes from intermittent to continuous as the final two Light Emitting Diodes (LED's) are illuminated on one side or both sides of the display. The system detection length from the rear of the vehicle is 0.3 meters to 1.5 meters. This area extends around the rear side of the vehicle.The system detection height from the ground is 0.2 meters to about 1.5 meters. The radio mutes when the system activates its audible tone. When the driver selects Reverse or Neutral the system scans for objects behind the vehicle using four sensors located in the rear bumper. Objects can be detected from up to 1.5 meters. A warning display above the rear window provides both visible and audible warnings indicating the range of the object. The system is active only when the vehicle is in reverse or neutral for vehicle speeds less than 16 Km/h (10 mph). If the vehicles Parking/Emergency Brake is applied, the system is deactivated. The display contains two sets of yellow and red Light Emitting Diode's (LED's) that the driver can see in the rear view mirror. Each side of the vehicle has its own warning LED's. The system provides a visual warning by illuminating one or more yellow LED's as the vehicle gets closer to the object. As the vehicle continues to approaches the object, one red LED is illuminated and the system emits a series of short beeps. The tone will remain constant and both red LED's are illuminated once the vehicle is within 12 inches (30.5 cm) of the object. The system can be turned ON or OFF through the Electronic Vehicle Information Center (EVIC) when the vehicle is in PARK. If the park assist system is turned OFF, a single chime will sound and the EVIC will display the following message REAR PARK ASSIST OFF, when the vehicle is in reverse. - Ensure that the rear bumper is free of dirt and debris to keep the system operating properly. - Jackhammers, large trucks, and other vibrations could affect the performance of the system. - Ensure that the parking brake is not applied. If Service Park Assist System appears in the EVIC after making sure the rear bumper is clean, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3542 proceed to diagnose the system using a scan tool and the appropriate diagnostic information. Power Door Lock System When the BCM receives input for a lock request from a door lock switch, RKE or cylinder lock switch (only with VTSS), it will turn the lock drivers on for a specified time of 375 msec. If the request is there beyond 375 msec, the BCM considers the door lock signal stuck. Once a door lock or unlock signal is stuck for longer than 10 seconds, the BCM will set a trouble code and the signal input is ignored until the stuck condition disappears. The door lock switches provide a variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond to that command. DOOR LOCK INHIBIT When the key is in the ignition and in any position and either front door is open, the door lock switches LOCK functions are disabled. The UNLOCK functions are still functional. This protects against locking the vehicle with the keys still in the ignition. The RKE key fob will still lock the doors as usual. After the key is removed from the ignition or the doors are closed, the power door locks will operate normally. AUTOMATIC DOOR LOCKS This feature can be enabled or disabled by using either the DRBIII(R) or the customer programming method. When enabled all the doors will lock when the vehicle reaches a speed greater than 18 MPH (29 KMH) and all the doors are closed. If a door is opened and the vehicle slows to below 18 MPH (29 KMH), the door locks will operate again once all doors are closed and the speed is above 18 MPH (29 KMH). REMOTE KEYLESS ENTRY (RKE) The RKE transmitter uses radio frequency signals to communicate with the SKREEM module. The SKREEM is on the PCI bus. When the operator presses a button on the transmitter, it sends a specific request to the SKREEM. In turn the SKREEM sends the appropriate request over the PCI Bus to the: - Body Control Module (BCM) to control the door lock and unlock functions, the arming and disarming of the Vehicle Theft Security System (if equipped), and the activation of illuminated entry. - Integrated Power Module (IPM) to activate the park lamps, the headlamps, and the horn for horn chirp. - Power Liftgate Module (PLGM) to control the liftgate operation (double press). - Power Sliding Door Module (PSDM) to control the sliding door operation (double press). After pressing the lock button on the RKE transmitter, all of the door locks will lock, the illuminated entry will turn off (providing all doors are closed), and the vehicle theft security system (if equipped) will arm. After pressing the unlock button, on the RKE transmitter, one time, the driver doorlock will unlock, the illuminated entry will turn on the courtesy lamps, and the vehicle theft security system system (if equipped) will disarm. After pressing the unlock button a second time, the remaining door locks will unlock. The EVIC or the DRBIII(R) can reprogram this feature to unlock all of the door locks with one press of the unlock button. If the vehicle is equipped with the memory system, the memory message will identify which transmitter (1 or 2) sent the signal. The SKREEM is capable of retaining up to 8 individual access codes (8 transmitters). If the PRNDL is in any position except park, the SKREEM will disable the RKE. The 3 or 6 button transmitter uses 1-CR2032 battery. The minimum battery life is approximately 5 years based on 20 transmissions a day at 84° F (25° C). Use the DRBIII(R) or the Miller Tool 9001 RF Detector to test the RKE transmitter. Use the DRBIII(R) or the customer programming method to program the RKE system. However, the SKREEM will only allow RKE programming when the ignition is in the on position, the PRNDL is in park position, and the VTSS (if equipped) is disarmed. PANIC FUNCTION Pressing the panic button on the RKE transmitter will cause the headlamp relay, the park lamp relay, and the horn relay to pulsate, which in turn will cause the exterior lamps to flash and the horn to sound intermittently. It will also cause the courtesy lamp relay to actuate, turning on the courtesy lamps. Pressing the panic button again stops the headlamps and the park lamps from flashing and the horn from sounding. However, the courtesy lamps will remain on until either the BCM times out lamp operation or until the ignition is turned on. The panic feature operates for three minutes at a time, unless the operator cancels it, or the ignition is turned on. Actuating the headlamp, horn, park lamps, and courtesy lamps with the DRBIII(R) will verify if the circuits and the Integrated Power Module are OK. If the panic feature is still inoperable with all transmitters, it will be necessary to replace the SKREEM. If the function is inoperable with just one transmitter, then replace only that transmitter. ROLLING CODE The rolling code feature changes part of the transmitter message each time that it is used. The transmitter message and the receiver message increment together. Under certain conditions with a rolling code system (pressing a button on the RKE transmitter over 255 times outside the receiver range, battery replacement, etc.), the receiver and transmitter can fall out of synchronization. NOTE: The lock function works from the RKE transmitter even in an out of synchronization condition and therefore it could be verified by pressing the LOCK button on the RKE integrated key. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3543 To resynchronize, press and release the UNLOCK button on the RKE transmitter repeatedly (it may take up to eight cycles) while listening carefully for the power door locks in the vehicle to cycle, indicating that resynchronization has occurred. PROGRAMMABLE DOOR LOCK FEATURES - The RKE can be changed to unlock all doors with one press - The Automatic Door Locks can be enabled/ disabled - Auto Unlock on Exit can be enabled/disabled - RKE horn chirp on lock can be enabled/disabled - RKE optical chirp (turn signal lamps) can be enabled/disabled - Program a new RKE transmitter. - RKE linked to memory (if equipped with memory system) enabled/disabled (DRBIII(R) only). Allows memory to be operable only from the driver door switch. Rear Window Defog/Heated Mirror The defroster button located on the HVAC control controls the rear window defogger and the heated side view mirrors. When the defroster button is pushed, the HVAC control sends a bus message over the PCI bus to the Front Control Module (FCM) which controls the Rear Window Defogger relay. The defroster LED will illuminate when the defroster function is on. The defroster will function for 10 minutes or can be cycled off sooner by pressing the defroster button again. Vehicle Theft Security System The Vehicle Theft Security System (VTSS) is part of the Body Control Module (BCM). The BCM monitors the vehicle doors, liftgate (export only), hood (export only), and the ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps and the VTSS indicator lamp. The VTSS does not prevent engine operation, this is done with the Sentry Key Remote Entry Module (SKREEM). The VTSS indicator lamp will flash for approximately 15 seconds during the arming process. If there is no interruption during the arming process, upon completion the VTSS indicator lamp will flash at a slower rate. When the BCM receives an input to trigger the alarm, the BCM will control the outputs of the headlamps, horn, and VTSS lamp for approximately 15 minutes. Arming (Active and Passive) Active arming occurs when the ignition key is removed, the RKE transmitter or door key cylinders are used to lock the vehicle doors, whether the doors are open or closed. The arming process is complete only after all doors are closed. Passive arming occurs when the ignition key is removed, the driver door is opened, and the doors are locked with the power door lock switch, and the door is closed. Disarming (Active and Passive) Active disarming occurs when the RKE transmitter is used to unlock the vehicle doors. This disarming will also halt the alarm once it has been activated. Passive disarming occurs upon normal vehicle entry (unlocking driver door with the key) or turning the ignition switch on with a valid ignition key. This disarming will also halt the alarm once it has been activated. Tamper Alert The VTSS tamper alert will sound the horn three times upon disarming after an initial alarming has occurred to indicate a tamper condition has occurred. Manual Override The system will not arm if the doors are locked using the manual lock control or if the locks are actuated by an inside occupant after the doors are closed. Diagnosis For complaints about the Vehicle Theft Alarm triggering on its own, use the DRBIII(R) and read the Last VTSS Cause status. Arming Before arming, all doors, liftgate, and the hood must be completely closed. The system can only be armed by locking the doors with the RKE transmitter. Disarming To disarm the alarm system, use the RKE transmitter or turn the ignition on with a valid ignition key. This will also halt the alarm once it has been activated. NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes on after ignition on and stays on, the PCI Bus Communication with the powertrain Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3544 control module has possibly been lost. Power Folding Mirrors The power folding mirrors are powered to two positions: folded and unfolded. The driver may choose fold or unfold with a switch that is located on the right side of the steering column. The folding mirror switch grounds a sense wire that comes from the Body Control Module when it is placed in the fold position. The mirrors will move to the position designated by the switch whether the ignition switch is the On or Off position and both front doors are closed. When the Power Folding Mirror switch is left in the fold position during a vehicle exit the mirrors will automatically unfold then refold after both front doors are closed. This is to prevent mirror contact with either front door when opened. When opening either front door, the Body Control Module will unfold the mirrors in the following manner depending on which front door is opened. If the driver door is opened, only the driver side mirror will unfold. If the passenger door is opened, both mirrors will unfold. The passenger mirror is prevented from unfolding when the driver's door is opened by the Passenger Folding Mirror Relay, which opens the driver circuit to the passenger side mirror. Power Liftgate System POWER LIFTGATE The power liftgate (PLG) system is activated through the use of the following: remote keyless entry (RKE), overhead console switches, outside liftgate handle switch or the DRBIII(R). These inputs are hardwired to the body control module (BCM) and can be monitored with a diagnostic tool. The BCM will send the message via PCI bus to the power liftgate module (PLGM). The liftgate must be in the full open or full closed position to operate. Once the BCM sends a button activation message to the PLGM, the module shall read all inputs, outputs and vehicle conditions to determine whether it shall open, close or inhibit the PLG operation. Once the PLGM determines the vehicle conditions are safe for operation, the PLGM will initiate a chime for 2 seconds prior to the liftgate activation and 2 seconds during the open or close cycle. During an opening or closing cycle, the PLGM can detect an obstacle present should it meet sufficient resistance by the hall effect sensors (integrated in the gear motor assembly GMA).During an open cycle, multiple liftgate activations (RKE, overhead console, B pillar) are ignored until the liftgate reaches the full open position. However, during a close cycle, a 2nd liftgate activation (RKE, overhead console, B pillar) will reverse the liftgate to the full open position. If the engine is cranked during a power open/close the PLG will pause then resume after engine cranking. In addition, if the vehicle is placed in gear during an open cycle, the PLG shall reverse direction and begin closing. If the vehicle is placed in gear during a closing cycle, the PLG shall continue closing until fully closed. If the outside handle is activated during an open cycle, the PLG will become a full manual liftgate. If the outside handle is activated during a close cycle, the PLG shall reverse direction of travel to the full open position. DIAGNOSTIC FEATURES The PLG can be flashed on vehicle via PCI bus with a DRBIII(R) diagnostic tool. The DRBIII(R) can read all inputs, actuate all outputs, read module information, and read diagnostic trouble codes. As a reminder, some DTC's can be set during normal PLG operation. SYSTEM INHIBITORS 1. Battery voltage too high or too low (above 16 V, below 9.5 V) 2. Vehicle in gear 3. Vehicle speed > 0 mph/km/h 4. Outside temperature too high, above 143° F (62° C) or too low, below -12° F (-24° C). 5. O/H console lockout will inhibit the B pillar switches only. 6. Liftgate locked will inhibit all interior switches from opening (overhead console). A locked liftgate can be power closed. 7. Pinch Sensor switch stuck shall inhibit the power close feature. Power Sliding Door System POWER SLIDING DOOR The Power Sliding Door (PSD) system is activated through the use of the following: Remote Keyless Entry (RKE), overhead console switches, B pillar switches or the DRBIII(R). These inputs are hardwired to the body control module (BCM) and can be monitored with a diagnostic tool. The BCM will send the message via PCI bus to the power sliding door module (PSDM). The sliding door must be in the full open or full closed position to operate. Once the BCM sends a button activation message to the PSDM, the module shall read all inputs, outputs and vehicle conditions to determine whether it shall open, close or inhibit the PSD operation. During an opening or closing cycle, the PSDM can detect an obstacle present should it meet sufficient resistance by the hall effect sensors (integrated in the drive motor). During an open cycle, multiple door activations (RKE, overhead console, B pillar) are ignored until the door reaches the full open position. However, during a close cycle, a 2nd door activation (RKE, overhead console, B pillar) will reverse the door to the full open position. If the engine is cranked during a power open/close the PSD will pause then resume after engine cranking. In addition, if the vehicle is placed in gear during an open cycle, the PSD shall reverse direction and begin closing. If the vehicle is placed in gear during a closing cycle, the PSD shall continue closing until fully closed. If the inside or outside handle is activated during an open or close cycle, the PSD will become a full manual sliding door. The child lockout is mechanical only and has no effect on the B-pillar switch as it did in previous models. There is only one part number for the power sliding door module (PSDM). The driver sliding door harness has an additional ground circuit which will Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3545 identify it as the driver side. This eliminates the need for a left and a right side module. DIAGNOSTIC FEATURES The PSDM can be flashed on vehicle via PCI bus with a DRBIII(R) diagnostic tool. The DRBIII(R) can read all inputs, actuate all outputs, read module information, and read diagnostic trouble codes. As a reminder, some DTC's can be set during normal PSD operation. SYSTEM INHIBITORS 1. Battery voltage too high or too low (above 16 V, below 9.5 V) 2. Vehicle in gear 3. Vehicle speed > 0 mph/km/h 4. O/H console lockout will inhibit the B pillar switches 5. Doors locked will inhibit all interior switches from opening (Overhead Console, B Pillar). A locked sliding door can be power closed. Wiper System FRONT WIPER The front wiper/washer system consists of the following features: lo-hi-speed, mist wipers, intermittent wipers and wipe after wash. The front wiper system is only active when the ignition switch is in the RUN/ACC position. The vehicle operator selects the front wiper function using the front wiper switch (a resistive multiplexed stalk switch) which is integral to the Multi-Function Switch. The front wiper switch is hardwired to the Body Control Module (BCM). Upon receiving a wiper switch signal, the BCM sends a PCI Bus message to the Front Control Module (FCM). The FCM controls the ON/ OFF relay, the HIGH/LOW relay and the front and rear washer pump motors. The Wiper system utilizes the BCM to control the on/off and hi/low relays for the low and hi speed wiper functions, intermittent wiper delay as the switch position changes, pulse wipe, wipe after wash mode and wiper motor functions. The BCM uses the vehicle speed input to double the usual delay time below 10 MPH (16 KPH). SPEED SENSITIVE INTERMITTENT WIPE MODE There are 5 individual delay time settings with a minimum delay of 1.7 seconds to a maximum of 18.4 seconds. When the vehicle speed is under 10 MPH (16 KPH), the delay time is doubled, providing a delay range of 3.4 seconds to 36.8 seconds. PULSE WIPE When the wiper is in the off position and the driver presses the wash button for more than 0.062 seconds, but less than 0.5 seconds,2 wipe cycles in low speed mode will be provided. PARK AFTER IGNITION OFF Because the wiper relays are powered from the battery, the BCM can run the wipers to park after the ignition is turned off. WIPE AFTER WASH When the driver presses the wash button for over 0.5 seconds and releases it, the wiper will continue to run for 2 additional wipe cycles. REAR WIPER The rear wiper/washer system consists of the following features: mist wipers, intermittent wipers and wipe after wash. The rear wiper system is only active when the ignition switch is in the RUN/ACC position. The vehicle operator selects the rear wiper function using one of the three buttons on the dash mounted rear wiper switch. The rear wiper switch is hardwired to the Body Control Module (BCM). Upon receiving a wiper switch signal, the BCM provides 12 volts to the rear wiper motor. Rear washer occurs when the BCM receives a rear washer switch ON input. The BCM sends a PCI Bus message to the FCM requesting rear washer on. The FCM activates the rear washer by providing a ground for the rear washer motor. SPEED SENSITIVE INTERMITTENT WIPE MODE The delay setting of the rear wiper system is based solely on the vehicle speed. The delay time is defined as the amount of time from the start of a wipe to the beginning of the next wipe. The rear wiper system delay time is based on the following: 7.75 - (MPH x 0.05) = Seconds delay Examples:At zero (0) MPH the delay is 7.75 seconds. At 100 MPH the delay is 2.75 seconds. WIPE AFTER WASH When the driver presses the wash button for over 1.5 seconds and releases it,the wiper will continue to run for 2 additional wipe cycles. Telecommunications HANDS FREE PHONE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 3546 OVERVIEW The vehicle telecommunications system consists of a Hands Free Module, Rear View Mirror, and a Blue-tooth Hands Free Profile enabled cell phone. The system allows vehicle occupants to use voice recognition technology to make, receive and screen phone calls without physically handling a cell phone. The system has a programmable phone book that can prevent the vehicle operator from becoming distracted searching for a specific number. Seven different wireless phones can be programmed to operate each individual system. Each of the seven phones is given a rank of priority when programmed. OPERATION Incoming phone messages are transmitted to the vehicle occupants through the vehicles audio system when the ignition is on and the wireless phone is on. Upon receiving the signal from an incoming phone call, the vehicle audio system will fade out the current CD/DVD or radio output. The vehicle occupants are then directed to accept or reject the call.Outgoing audio messages are received through the microphone located in the rearview mirror then transmitted via hardwire to the Hands Free Module and finally transmitted through the wireless phone. Volume of the voice prompts and incoming conversation is controlled using the vehicles radio audio controls and steering wheel controls if equipped. The rear view mirror contains a Phone Switch, Voice Recognition Switch and a microphone. The rear view mirror transmits these inputs via hardwired circuits to the Hands Free Module. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Air Bag System Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Any Station Preset Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3549 Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3550 POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Test 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3551 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Pause/Play Switch Inoperative Test 1 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3552 Test 1 SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Remote Radio Controls Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3553 Test 4 - 7 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3554 Test 8 - 9 SYMPTOM REMOTE RADIO CONTROLS INOPERATIVE POSSIBLE CAUSES - Open radio control MUX circuit at the switch - Open radio control MUX return circuit at the switch - Remote radio switch - Body control module - internal short - Open clockspring - Open radio control MUX circuit - Open radio control MUX return circuit - Body control module - open internal Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3555 Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3556 POSSIBLE CAUSES - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure ATC Head LED(s)/Backlighting Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3557 Test 1 - 3 Test 4 - 5 SYMPTOM ATC HEAD LED(S)/BACK LIGHTING INOPERATIVE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3558 POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - ATC - LED(s) inoperative - ATC - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3559 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3560 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3561 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3562 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3563 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM FUSE #10 - Fused front blower motor relay output circuit shorted to ground - Blower motor shorted to ground - Front blower power module shorted to ground - Ground circuit open - Blower motor control circuit shorted to voltage - Blower motor control circuit open - Front blower power module open - Automatic temperature control module open - Check blower motor operation - Front blower power module open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3564 Test 1 Test 2 SYMPTOM FRONT BLOWER RUNS AT ONLY ONE SPEED Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3565 POSSIBLE CAUSES - Blower motor control circuit shorted to ground - Automatic temperature control module - Front blower power module HVAC System Test Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3566 Test 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3567 Test 6 Test 7 SYMPTOM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3568 HVAC SYSTEM TEST POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active ATC DTC's - Check for AC cooldown test fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear ATC Switch LED(s)/Backlighting Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3569 Test 4 - 5 SYMPTOM REAR ATC SWITCH LED(S)/BACK LIGHTING INOPERATIVE POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - Rear ATC switch - LED(s) inoperative - Rear ATC switch - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3570 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3571 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3572 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3573 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3574 Test 15 - 16 SYMPTOM REAR BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM Fuse #12 - Fused rear blower relay output circuit shorted to ground - Blower motor shorted to ground - Rear blower motor power module shorted to ground - Ground circuit open - Rear blower motor control circuit shorted to voltage - Rear blower motor control circuit open - Rear blower motor power module open - Automatic temperature control module open - Check blower motor operation - Rear blower motor power module open - IPM - open circuit - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3575 Test 1 Test 2 SYMPTOM REAR BLOWER RUNS AT ONLY ONE SPEED POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3576 - Rear blower motor control circuit shorted to ground - Automatic temperature control module - Rear blower motor power module Chime Inoperative Test 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE POSSIBLE CAUSES - Use DRB to actuate chime - Chime driver circuit - open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3577 - Chime driver circuit - short to ground - Chime driver circuit - short to voltage - Instrument cluster - BCM Key In Ignition and Drivers Door Open Chime Not Operating Properly Test 1 - 3 SYMPTOM KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME NOT OPERATING PROPERLY POSSIBLE CAUSES - DRB chime actuator - Driver door ajar status - Ignition switch - Body control module Vehicle Speed Warning Chime Problem Test 1 SYMPTOM PROBLEM WITH THE VEHICLE SPEED WARNING CHIME POSSIBLE CAUSES - Incorrect country code programmed in BCM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3578 - Body control module Left Front Door Ajar Switch Sense Circuit Open Test 1 - 4 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Left front door ajar switch ground circuit open - Left front door (lock motor) ajar switch - Left front door ajar switch sense circuit open - Body control module internal malfunction Left Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3579 Test 1 - 2 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left front door (lock motor) ajar switch shorted to ground - Left front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Left Sliding Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3580 Test 1 - 3 Test 4 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Left sliding door ajar switch sense circuit open - Left sliding door ajar switch sense circuit open - Body control module internal malfunction Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3581 - Left sliding door lock motor/ajar switch (latch assy). Left Sliding Door Ajar Switch Sense Circuit Shorted to Ground Test 1 - 3 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left sliding door lock motor/ajar switch shorted to ground - Left sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Left sliding door lock motor/ajar switch (latch assy). Liftgate Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3582 Test 1 - 4 SYMPTOM LIFTGATE AJAR CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Liftgate ajar switch ground circuit open - Liftgate ajar switch (cinch/release motor) - Liftgate ajar switch sense circuit open - Body control module internal malfunction Liftgate Ajar Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3583 Test 1 - 2 SYMPTOM LIFTGATE AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Liftgate ajar switch shorted to ground - Liftgate ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3584 Test 1 - 4 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Right front door ajar switch ground circuit open - Right front door (lock motor) ajar switch - Right front door ajar switch sense circuit open - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3585 Test 1 - 2 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right front door (lock motor) ajar switch shorted to ground - Right front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Sliding Door Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3586 Test 1 - 3 Test 4 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Right sliding door ajar switch sense circuit open - Right sliding door ajar switch sense circuit open - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3587 Right Sliding Door Ajar Circuit Shorted to Ground Test 1 - 3 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right sliding door lock motor/ajar switch shorted to ground - Right sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) A/C Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3588 Test 1 - 2 Test 3 SYMPTOM A/C STATUS INDICATOR FLASHING - MTC POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Blend/Mode/Recirc Door Operation Improper -- Dual & Three-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3589 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3590 Test 4 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3591 Test 7 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3592 Test 10 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER -- DUAL & THREE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Passenger blend door actuator/linkage/door - Driver blend door actuator/linkage/door - Recirculation door actuator/linkage/door - Rear mode door actuator/linkage/door - Rear blend door actuator/linkage/door Blend/Mode/Recirc Door Operation Improper --Single-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3593 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3594 Test 4 - 7 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER --SINGLE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Blend door actuator/linkage/door - Recirculation door actuator/linkage/door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3595 Front A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Test 4 SYMPTOM FRONT A/C - HEATER CONTROL ILLUMINATION INOPERATIVE -MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - A/C - heater control module - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3596 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3597 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3598 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3599 Test 11 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3600 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #10 - Fused front blower motor relay output circuit shorted to ground - Front blower motor resistor block shorted to ground - Front blower motor resistor block shorted to ground - Blower motor - Blower motor - A/C - heater control module - Ground circuit open - Blower motor high driver circuit open - Front blower motor resistor block open - Front blower motor resistor block open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Motor Speeds Incorrect - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3601 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3602 Test 3 - 5 SYMPTOM FRONT BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Blower motor driver circuit(s) shorted to ground - Blower motor driver circuit(s) shorted to voltage - Blower motor driver circuits shorted together - A/C - heater control module - speeds incorrect - Blower motor driver circuit(s) open - Blower motor resistor block - open speed HVAC System Test - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3603 Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3604 Test 5 Test 5 SYMPTOM HVAC SYSTEM TEST - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3605 POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active HVAC DTC's and system tests fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3606 Test 4 - 5 SYMPTOM REAR A/C - HEATER CONTROL ILLUMINATION INOPERATIVE - MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - Inoperative bulb - Ground circuit open - Rear blower rear control switch - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3607 Test 1 - 2 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3608 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3609 Test 11 - 14 SYMPTOM REAR BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #12 - Fused rear blower motor relay output circuit shorted to ground - Blower motor - Ground circuit open - A/C - heater control module - Check for power to rear blower motor - Blower motor - Rear blower high speed circuit open - Rear blower motor high circuit open - Rear blower motor resistor block - IPM - open circuit Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3610 - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Motor Speeds Incorrect - MTC Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3611 Test 3 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3612 Test 6 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3613 Test 10 SYMPTOM REAR BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to ground - A/C - heater control module - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to voltage - Rear blower motor front control feed circuit shorted to voltage - Rear blower driver CKT(s) shorted to rear blower front control feed CKT - Rear blower motor driver circuits shorted together - A/C - heater control module - Rear blower motor driver circuit(s) open - Rear blower motor resistor block Rear Blower Rear Control Switch INOP In One or More Speeds - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3614 Test 1 - 2 Test 3 SYMPTOM REAR BLOWER REAR CONTROL SWITCH INOP IN ONE OR MORE SPEEDS - MTC POSSIBLE CAUSES - Rear blower motor driver circuit(s) open - Rear blower rear control switch - Rear blower motor front control feed circuit open - A/C - heater control module Recirc Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3615 Test 1 - 2 Test 3 SYMPTOM RECIRC STATUS INDICATOR FLASHING - MTC TEST NOTE This symptom is diagnosed using the test A/C STATUS INDICATOR FLASHING - MTC. POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Any PCI Bus Indicator Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3616 Test 1 - 4 SYMPTOM ANY PCI BUS INDICATOR INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - No response - instrument cluster - No response - ECM / PCM - Indicator inoperative - Instrument cluster Seat Belt Indicator Always On Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3617 Test 1 SYMPTOM SEAT BELT INDICATOR ALWAYS ON POSSIBLE CAUSES - ACM seat belt indicator command present - Instrument cluster Overhead Console Test 1 - 4 SYMPTOM REPAIRING CMTC DISPLAYS DOUBLE DASH (- - ) IN TEMP DISPLAY POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3618 - No response - PCI BUS - powertrain control module - CMTC BUS message failure - Compass mini-trip computer - Ambient temperature sensor - PCM ambient air temperature sensor DTC present - CMTC internal Left Cylinder Lock Switch Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3619 Test 4 - 5 SYMPTOM LEFT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - left cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - left cylinder lock switch MUX short to voltage Remote Keyless Entry Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3620 Test 1 - 4 Test 5 - 6 SYMPTOM REMOTE KEYLESS ENTRY INOPERATIVE POSSIBLE CAUSES - DTC present - SKREEM DTC present - Test transmitter with tester - RKE transmitter inoperative - RKE transmitter not programmed - SKREEM module - RKE inoperative - SKREEM module - RKE inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3621 Right Cylinder Lock Switch Inoperative Test 1 - 3 Test 4 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3622 SYMPTOM RIGHT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - right cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - right cylinder lock switch MUX short to voltage Power Doors - Liftgate Test 1 - 4 SYMPTOM POWER LIFTGATE INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Power Doors - Sliding Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3623 Test 1 - 4 SYMPTOM POWER SLIDING DOOR INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Alarm Trips On Its Own Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3624 Test 1 - 4 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - Last VTSS cause - Attempt to trip alarm - Intermittent condition Left Front Door Does Not Trip VTSS Test 1 SYMPTOM LEFT FRONT DOOR DOES NOT TRIP VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3625 POSSIBLE CAUSES - Body control module - Check DRBIII(R) for driver door ajar response Left Sliding Door Does Not Trip VTSS Test 1 SYMPTOM LEFT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Monitor DRBIII(R) for left sliding door ajar status - Body control module Right Front Door Does Not Trip VTSS Test 1 SYMPTOM RIGHT FRONT DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for passenger door ajar response - Body control module Right Sliding Door Does Not Trip VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3626 Test 1 SYMPTOM RIGHT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for right rear door ajar response - Body control module VTSS Will Not Arm Test 1 - 3 SYMPTOM VTSS WILL NOT ARM POSSIBLE CAUSES - Check the VTSS status - Check for BCM DTC's and VTSS arming inhibitors - Check for PCI BUS communication of instrument cluster and SKIM - Body control module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3627 Body Control Module: Component Tests and General Diagnostics Six Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation Road Testing ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. WARNING: REASSEMBLE ALL COMPONENTS BEFORE ROAD TESTING A VEHICLE. DO NOT TRY TO READ THE DRBIII(R) SCREEN OR OTHER TEST EQUIPMENT DURING A TEST DRIVE. DO NOT HANG THE DRBIII(R) OR OTHER TEST EQUIPMENT FROM THE REARVIEW MIRROR DURING A TEST DRIVE. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIII(R) OR OTHER TEST EQUIPMENT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Vehicle Preparation For Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Glossary of Terms ABS antilock brake system ACT actuator APS adjustable pedals system ATC automatic temperature control BCM body control module BPS bladder pressure sensor BTS belt tension sensor CAB controller antilock brake CMTC compass/mini-trip computer CPA connector positive assurance DAB driver airbag DCHA diesel cabin heater assist (cabin heater) DLC data link connector DTC diagnostic trouble code DR driver EBL electric back lite (rear window defogger) ECM engine control module EVIC electronic vehicle information center FCM front control module GCC Gulf Coast Countries HE hall effect HFM hands free module HVAC heater ventilation, air conditioning IPM integrated power module KNB knee blocker airbag LDU lower drive unit LHD left hand drive MIC mechanical instrument cluster MTC manual temperature control MSMAPM memory seat/mirror/adjustable pedals module NAV navigation NGC next generation controller OBD on board diagnostics OCM occupant classification module OCS occupant classification system OCSVR occupant classification system verification required ODO odometer ORC occupant restraint controller PAB passenger airbag PASS passenger PCI Programmable Communication Interface (vehicle communication bus) PCM powertrain control module PDC power distribution center PLG power liftgate Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3628 PLGM power liftgate module PSD power sliding door PSDM power sliding door module PWM pulse width modulated RHD Right Hand Drive RKE remote keyless entry RX receive SAB seat airbag SBS seat belt switch SBT seat belt tensioner SKREEM sentry key remote entry module SQUIB also called initiator (located inside airbag) SRS supplemental restraint system TCM transmission control module TPMS tire pressure monitor system TX transmit VFD vacuum fluorescent display VTSS vehicle theft security system Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3629 Body Control Module: Testing and Inspection Diagnostic Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes See: Testing and Inspection/Diagnostic Trouble Code Descriptions Diagnostic Trouble Code Tests and Associated Procedures For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures Air Bag System Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Any Station Preset Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3630 Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3631 POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Test 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3632 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Pause/Play Switch Inoperative Test 1 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3633 Test 1 SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Remote Radio Controls Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3634 Test 4 - 7 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3635 Test 8 - 9 SYMPTOM REMOTE RADIO CONTROLS INOPERATIVE POSSIBLE CAUSES - Open radio control MUX circuit at the switch - Open radio control MUX return circuit at the switch - Remote radio switch - Body control module - internal short - Open clockspring - Open radio control MUX circuit - Open radio control MUX return circuit - Body control module - open internal Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3636 Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3637 POSSIBLE CAUSES - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure ATC Head LED(s)/Backlighting Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3638 Test 1 - 3 Test 4 - 5 SYMPTOM ATC HEAD LED(S)/BACK LIGHTING INOPERATIVE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3639 POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - ATC - LED(s) inoperative - ATC - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3640 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3641 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3642 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3643 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3644 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM FUSE #10 - Fused front blower motor relay output circuit shorted to ground - Blower motor shorted to ground - Front blower power module shorted to ground - Ground circuit open - Blower motor control circuit shorted to voltage - Blower motor control circuit open - Front blower power module open - Automatic temperature control module open - Check blower motor operation - Front blower power module open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3645 Test 1 Test 2 SYMPTOM FRONT BLOWER RUNS AT ONLY ONE SPEED Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3646 POSSIBLE CAUSES - Blower motor control circuit shorted to ground - Automatic temperature control module - Front blower power module HVAC System Test Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3647 Test 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3648 Test 6 Test 7 SYMPTOM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3649 HVAC SYSTEM TEST POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active ATC DTC's - Check for AC cooldown test fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear ATC Switch LED(s)/Backlighting Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3650 Test 4 - 5 SYMPTOM REAR ATC SWITCH LED(S)/BACK LIGHTING INOPERATIVE POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - Rear ATC switch - LED(s) inoperative - Rear ATC switch - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3651 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3652 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3653 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3654 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3655 Test 15 - 16 SYMPTOM REAR BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM Fuse #12 - Fused rear blower relay output circuit shorted to ground - Blower motor shorted to ground - Rear blower motor power module shorted to ground - Ground circuit open - Rear blower motor control circuit shorted to voltage - Rear blower motor control circuit open - Rear blower motor power module open - Automatic temperature control module open - Check blower motor operation - Rear blower motor power module open - IPM - open circuit - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3656 Test 1 Test 2 SYMPTOM REAR BLOWER RUNS AT ONLY ONE SPEED POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3657 - Rear blower motor control circuit shorted to ground - Automatic temperature control module - Rear blower motor power module Chime Inoperative Test 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE POSSIBLE CAUSES - Use DRB to actuate chime - Chime driver circuit - open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3658 - Chime driver circuit - short to ground - Chime driver circuit - short to voltage - Instrument cluster - BCM Key In Ignition and Drivers Door Open Chime Not Operating Properly Test 1 - 3 SYMPTOM KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME NOT OPERATING PROPERLY POSSIBLE CAUSES - DRB chime actuator - Driver door ajar status - Ignition switch - Body control module Vehicle Speed Warning Chime Problem Test 1 SYMPTOM PROBLEM WITH THE VEHICLE SPEED WARNING CHIME POSSIBLE CAUSES - Incorrect country code programmed in BCM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3659 - Body control module Left Front Door Ajar Switch Sense Circuit Open Test 1 - 4 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Left front door ajar switch ground circuit open - Left front door (lock motor) ajar switch - Left front door ajar switch sense circuit open - Body control module internal malfunction Left Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3660 Test 1 - 2 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left front door (lock motor) ajar switch shorted to ground - Left front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Left Sliding Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3661 Test 1 - 3 Test 4 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Left sliding door ajar switch sense circuit open - Left sliding door ajar switch sense circuit open - Body control module internal malfunction Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3662 - Left sliding door lock motor/ajar switch (latch assy). Left Sliding Door Ajar Switch Sense Circuit Shorted to Ground Test 1 - 3 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left sliding door lock motor/ajar switch shorted to ground - Left sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Left sliding door lock motor/ajar switch (latch assy). Liftgate Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3663 Test 1 - 4 SYMPTOM LIFTGATE AJAR CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Liftgate ajar switch ground circuit open - Liftgate ajar switch (cinch/release motor) - Liftgate ajar switch sense circuit open - Body control module internal malfunction Liftgate Ajar Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3664 Test 1 - 2 SYMPTOM LIFTGATE AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Liftgate ajar switch shorted to ground - Liftgate ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3665 Test 1 - 4 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Right front door ajar switch ground circuit open - Right front door (lock motor) ajar switch - Right front door ajar switch sense circuit open - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3666 Test 1 - 2 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right front door (lock motor) ajar switch shorted to ground - Right front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Sliding Door Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3667 Test 1 - 3 Test 4 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Right sliding door ajar switch sense circuit open - Right sliding door ajar switch sense circuit open - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3668 Right Sliding Door Ajar Circuit Shorted to Ground Test 1 - 3 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right sliding door lock motor/ajar switch shorted to ground - Right sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) A/C Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3669 Test 1 - 2 Test 3 SYMPTOM A/C STATUS INDICATOR FLASHING - MTC POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Blend/Mode/Recirc Door Operation Improper -- Dual & Three-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3670 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3671 Test 4 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3672 Test 7 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3673 Test 10 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER -- DUAL & THREE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Passenger blend door actuator/linkage/door - Driver blend door actuator/linkage/door - Recirculation door actuator/linkage/door - Rear mode door actuator/linkage/door - Rear blend door actuator/linkage/door Blend/Mode/Recirc Door Operation Improper --Single-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3674 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3675 Test 4 - 7 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER --SINGLE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Blend door actuator/linkage/door - Recirculation door actuator/linkage/door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3676 Front A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Test 4 SYMPTOM FRONT A/C - HEATER CONTROL ILLUMINATION INOPERATIVE -MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - A/C - heater control module - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3677 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3678 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3679 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3680 Test 11 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3681 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #10 - Fused front blower motor relay output circuit shorted to ground - Front blower motor resistor block shorted to ground - Front blower motor resistor block shorted to ground - Blower motor - Blower motor - A/C - heater control module - Ground circuit open - Blower motor high driver circuit open - Front blower motor resistor block open - Front blower motor resistor block open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Motor Speeds Incorrect - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3682 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3683 Test 3 - 5 SYMPTOM FRONT BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Blower motor driver circuit(s) shorted to ground - Blower motor driver circuit(s) shorted to voltage - Blower motor driver circuits shorted together - A/C - heater control module - speeds incorrect - Blower motor driver circuit(s) open - Blower motor resistor block - open speed HVAC System Test - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3684 Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3685 Test 5 Test 5 SYMPTOM HVAC SYSTEM TEST - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3686 POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active HVAC DTC's and system tests fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3687 Test 4 - 5 SYMPTOM REAR A/C - HEATER CONTROL ILLUMINATION INOPERATIVE - MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - Inoperative bulb - Ground circuit open - Rear blower rear control switch - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3688 Test 1 - 2 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3689 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3690 Test 11 - 14 SYMPTOM REAR BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #12 - Fused rear blower motor relay output circuit shorted to ground - Blower motor - Ground circuit open - A/C - heater control module - Check for power to rear blower motor - Blower motor - Rear blower high speed circuit open - Rear blower motor high circuit open - Rear blower motor resistor block - IPM - open circuit Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3691 - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Motor Speeds Incorrect - MTC Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3692 Test 3 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3693 Test 6 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3694 Test 10 SYMPTOM REAR BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to ground - A/C - heater control module - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to voltage - Rear blower motor front control feed circuit shorted to voltage - Rear blower driver CKT(s) shorted to rear blower front control feed CKT - Rear blower motor driver circuits shorted together - A/C - heater control module - Rear blower motor driver circuit(s) open - Rear blower motor resistor block Rear Blower Rear Control Switch INOP In One or More Speeds - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3695 Test 1 - 2 Test 3 SYMPTOM REAR BLOWER REAR CONTROL SWITCH INOP IN ONE OR MORE SPEEDS - MTC POSSIBLE CAUSES - Rear blower motor driver circuit(s) open - Rear blower rear control switch - Rear blower motor front control feed circuit open - A/C - heater control module Recirc Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3696 Test 1 - 2 Test 3 SYMPTOM RECIRC STATUS INDICATOR FLASHING - MTC TEST NOTE This symptom is diagnosed using the test A/C STATUS INDICATOR FLASHING - MTC. POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Any PCI Bus Indicator Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3697 Test 1 - 4 SYMPTOM ANY PCI BUS INDICATOR INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - No response - instrument cluster - No response - ECM / PCM - Indicator inoperative - Instrument cluster Seat Belt Indicator Always On Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3698 Test 1 SYMPTOM SEAT BELT INDICATOR ALWAYS ON POSSIBLE CAUSES - ACM seat belt indicator command present - Instrument cluster Overhead Console Test 1 - 4 SYMPTOM REPAIRING CMTC DISPLAYS DOUBLE DASH (- - ) IN TEMP DISPLAY POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3699 - No response - PCI BUS - powertrain control module - CMTC BUS message failure - Compass mini-trip computer - Ambient temperature sensor - PCM ambient air temperature sensor DTC present - CMTC internal Left Cylinder Lock Switch Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3700 Test 4 - 5 SYMPTOM LEFT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - left cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - left cylinder lock switch MUX short to voltage Remote Keyless Entry Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3701 Test 1 - 4 Test 5 - 6 SYMPTOM REMOTE KEYLESS ENTRY INOPERATIVE POSSIBLE CAUSES - DTC present - SKREEM DTC present - Test transmitter with tester - RKE transmitter inoperative - RKE transmitter not programmed - SKREEM module - RKE inoperative - SKREEM module - RKE inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3702 Right Cylinder Lock Switch Inoperative Test 1 - 3 Test 4 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3703 SYMPTOM RIGHT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - right cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - right cylinder lock switch MUX short to voltage Power Doors - Liftgate Test 1 - 4 SYMPTOM POWER LIFTGATE INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Power Doors - Sliding Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3704 Test 1 - 4 SYMPTOM POWER SLIDING DOOR INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Alarm Trips On Its Own Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3705 Test 1 - 4 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - Last VTSS cause - Attempt to trip alarm - Intermittent condition Left Front Door Does Not Trip VTSS Test 1 SYMPTOM LEFT FRONT DOOR DOES NOT TRIP VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3706 POSSIBLE CAUSES - Body control module - Check DRBIII(R) for driver door ajar response Left Sliding Door Does Not Trip VTSS Test 1 SYMPTOM LEFT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Monitor DRBIII(R) for left sliding door ajar status - Body control module Right Front Door Does Not Trip VTSS Test 1 SYMPTOM RIGHT FRONT DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for passenger door ajar response - Body control module Right Sliding Door Does Not Trip VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3707 Test 1 SYMPTOM RIGHT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for right rear door ajar response - Body control module VTSS Will Not Arm Test 1 - 3 SYMPTOM VTSS WILL NOT ARM POSSIBLE CAUSES - Check the VTSS status - Check for BCM DTC's and VTSS arming inhibitors - Check for PCI BUS communication of instrument cluster and SKIM - Body control module Six Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3708 - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation Road Testing ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. WARNING: REASSEMBLE ALL COMPONENTS BEFORE ROAD TESTING A VEHICLE. DO NOT TRY TO READ THE DRBIII(R) SCREEN OR OTHER TEST EQUIPMENT DURING A TEST DRIVE. DO NOT HANG THE DRBIII(R) OR OTHER TEST EQUIPMENT FROM THE REARVIEW MIRROR DURING A TEST DRIVE. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIII(R) OR OTHER TEST EQUIPMENT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Vehicle Preparation For Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Glossary of Terms ABS antilock brake system ACT actuator APS adjustable pedals system ATC automatic temperature control BCM body control module BPS bladder pressure sensor BTS belt tension sensor CAB controller antilock brake CMTC compass/mini-trip computer CPA connector positive assurance DAB driver airbag DCHA diesel cabin heater assist (cabin heater) DLC data link connector DTC diagnostic trouble code DR driver EBL electric back lite (rear window defogger) ECM engine control module EVIC electronic vehicle information center FCM front control module GCC Gulf Coast Countries HE hall effect HFM hands free module HVAC heater ventilation, air conditioning IPM integrated power module KNB knee blocker airbag LDU lower drive unit LHD left hand drive MIC mechanical instrument cluster MTC manual temperature control MSMAPM memory seat/mirror/adjustable pedals module NAV navigation NGC next generation controller OBD on board diagnostics OCM occupant classification module OCS occupant classification system OCSVR occupant classification system verification required ODO odometer ORC occupant restraint controller PAB passenger airbag PASS passenger PCI Programmable Communication Interface (vehicle communication bus) PCM powertrain control module PDC power distribution center PLG power liftgate PLGM power liftgate module PSD power sliding door PSDM power sliding door module PWM pulse width modulated RHD Right Hand Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3709 RKE remote keyless entry RX receive SAB seat airbag SBS seat belt switch SBT seat belt tensioner SKREEM sentry key remote entry module SQUIB also called initiator (located inside airbag) SRS supplemental restraint system TCM transmission control module TPMS tire pressure monitor system TX transmit VFD vacuum fluorescent display VTSS vehicle theft security system DRB III Error Messages and Blank Screen DRBIII(R) ERROR MESSAGES Under normal operation, the DRBIII(R) will display one of only two error messages: user-requested WARM Boot or User-Requested COLD Boot. If the DRBIII(R) should display any other error message, record the entire display and call the STAR Center. This is a sample of such an error message display: ver:2.14 date: 26 Jul93 file: key_iff.cc date: Jul26 1993 line: 548 err: 0xi User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRBIII(R) DOES NOT POWER UP (BLANK SCREEN) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRBIII(R). Check for proper grounds at DLC cavities 4 and 5. If all connections are proper between the DRBIII(R) and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRBIII(R) may be the result or a faulty cable or vehicle wiring. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. DRB III Safety Information WARNING: EXCEEDING THE LIMITS OF THE DRBIII(R) MULTIMETER IS DANGEROUS. READ ALL DRBIII(R) INSTRUCTIONS BEFORE USING THE MULTIMETER. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3710 - Follow the vehicle manufacturer s service specifications at all times. - Do not use the DRBIII(R) if it has been damaged. - Do not use the test leads if the insulation is damaged or if metal is exposed. - To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. - Choose the proper range and functions for the measurement. Do not try voltage or current measurement that may exceed the rated capacity. - Do not exceed the limits shown in the table below: *Ohms cannot be measured if voltage is present. Ohms can be measured only in a non-powered circuit. - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10 A. - When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. - When measuring current, connect the meter in series with the load. - Disconnect the live test lead before disconnecting the common test lead. - When using the meter function, keep the DRBIII(R) away from spark plug or coil wires to avoid measuring error from outside interference. KDB Lab Scope Pattern Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 3711 PCI Bus Lab Scope Pattern Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 3712 Body Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lower instrument panel silencer. 3. Remove the knee blocker and reinforcement. 4. Disconnect the five wire connectors from the bottom of the Body Control Module (BCM). 5. Move bulkhead wiring aside. 6. Remove the screws holding the BCM to the bulkhead. 7. Remove the BCM from the mounting bracket. INSTALLATION 1. Install the BCM to the mounting bracket. 2. Install the screws holding the BCM to the bulkhead. 3. Connect the five wire connectors to the bottom of the Body Control Module (BCM). 4. Install the knee blocker and reinforcement. 5. Install the lower instrument panel silencer. 6. Connect the battery negative cable. 7. Verify proper operation of BCM and its functions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 3713 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRBIII(R) (diagnostic read-out box) Jumper wires Ohmmeter Voltmeter Sentry Key Tester Test Light 8443 SRS Airbag System Load Tool 9077 Occupant Classification Seat Weights Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 3718 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3719 Camshaft Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3720 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor EGR/CAM Sensor 2.4L The camshaft position sensor for the 3.3/3.8L is mounted in the front of the timing case cover and the camshaft position sensor for the 2.4L is mounted on the end of the cylinder head. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3721 Camshaft Position Sensor The camshaft position sensor provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it (Fig. 2). The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. Camshaft Position Sensor When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3722 Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the sensor. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs on represent which cylinder the flat spot and notches identify, they do not indicate TDC position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3723 NGC Typical Scope Patterns Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3724 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. Air Box Cover 2. Remove the air box cover and inlet tube. Camshaft Position Sensor 3. Disconnect camshaft position sensor electrical connector from the wiring harness connector. 4. Remove bolt holding sensor. 5. Rotate sensor away from block. 6. Pull sensor up out of the chain case cover. Do not pull on the sensor wiring. There is an O-ring on the body of the sensor. The O-ring may make removal difficult. A light tap to top of sensor prior to removal may reduce force needed for removal. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3725 Camshaft Position Sensor And Spacer If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. While holding the sensor in this position, install and tighten the retaining bolt 14 N.m (125 in. lbs.) torque. 4. Connect camshaft position sensor electrical connector to harness connector. 5. Install the air box cover and inlet hose. 6. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations 3.3L & 3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 3733 Crankshaft Position Sensor: Connector Locations Starter Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 3734 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3735 Crankshaft Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3736 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR Crankshaft Sensor 2.4L The 2.4L crankshaft sensor is located on the rear of the engine near the accessory drive belt. The 3.3L/3.8L crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3737 Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3738 NGC Typical Scope Patterns Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Component Locations > Page 3743 Data Link Connector: Connector Locations Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Component Locations > Page 3744 Right Side Kick Panel RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Connector Views Data Link Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Page 3747 Data Link Connector: Description and Operation Data Link Connector The data link connector is located inside the vehicle, below instrument panel next to the center column. The data link connector (diagnostic connector) links the DRB scan tool with the Powertrain Control Module (PCM). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Technical Service Bulletins > Safety Systems - Inadvertent Damage/Disabling Electronic Throttle Actuator: Technical Service Bulletins Safety Systems - Inadvertent Damage/Disabling NUMBER: 08-027-04 GROUP: Electrical DATE: July 30, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-017-01, DATED SEPTEMBER 21, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND YEARS. SUBJECT: Safety Systems - Vehicle Modifications/Repair MODELS: 2002 - **2003** (AB) Ram Van/Wagon 2002 - **2004** (AN) Dakota 2002 (BR/BE) Ram Pickup **2004 - 2005 (CS) Pacifica** 2002 - **2003** (DN) Durango **2003 - 2005 (DR/DH) Ram Pickup** **2004 - 2005 (HB) Durange 2002 - **2005** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 2002 - **2005** (KJ) Liberty 2002 - **2004** (LH) Concorde/Intrepid/300M **2005 (LX) 300/Magnum ** **2005 (ND) Dakota** 2002 (PG) PT Cruiser (International Markets) 2002 - **2005** (PL) Neon 2002 - **2003** (PR) Prowler 2002 - **2005** (PT) Chrysler PT Cruiser 2002 - **2005** (RS) Town & Country/Caravan/Voyager 2002 - **2005** (RG) Chrysler Voyager (International Markets) 2002 (SR) Viper 2002 - **2005** (ST) Sebring Coupe/Stratus Coupe 2002 - **2005** (TJ) Wrangler **2002 - 2005 (VA) Sprinter** 2002 - **2004** (WJ) Grand Cherokee **2005 (WK) Grand Cherokee** Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Actuator > Component Information > Technical Service Bulletins > Safety Systems - Inadvertent Damage/Disabling > Page 3752 2002 - **2004** (WG) Grand Cherokee (International Markets) **2005 (WH) Grand Cherokee (International Markets)** **2003 - 2005 (ZB) Viper** **2004 - 2005 (ZH) Crossfire** DISCUSSION: Current DaimlerChrysler vehicles may contain any or all of the following safety Systems: driver airbags, passenger airbags, side curtain airbags, side seat airbags, seat belt pre-tensioners, anti-lock brakes, electronic throttle control, or traction control. All these systems contain multiple sophisticated sensitive electrical and mechanical components. The location and function of all safety system components must be determined before performing repairs; including accident, mechanical or electrical, or vehicle modifications such as adding an after-market sunroof. WARNING: ANY INADVERTENT SAFETY SYSTEM COMPONENT OR ASSOCIATED WIRING DAMAGE/MODIFICATION OR COMPONENT LOCATION CHANGE MAY DISABLE ANY OF THE SAFETY SYSTEMS. Refer to the appropriate vehicle Service Information to determine location and function of all safety systems before servicing vehicle. All systems should be checked for functionality after the vehicle modifications/repairs are complete. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs Engine Control Module: Technical Service Bulletins Engine Controls - Programming Generic PCMs NUMBER: 18-029-07 GROUP: Vehicle Performance DATE: April 26, 2007 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-006-04 REV. B, DATED SEPTEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A MINOR REVISION AND **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT UPDATED PL PARTS APPLICATIONS. SUBJECT: Generic Powertrain Control Module (PCM) Procedure OVERVIEW: This bulletin involves programming a generic PCM with software. MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR) Ram Truck 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004-2005 (KJ) Liberty 2004 - 2005 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2004-2005 (PL) Neon 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2005 (TJ) Wrangler Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3757 NOTE: Refer to the table for specific applications. DISCUSSION: Mopar(R) is currently phasing out pre-programmed PCMs for the vehicles listed. New modules will no longer be pre-programmed when received from Mopar(R). Replacement of future PCMs will require programming utilizing the DRBIII(R) and TechCONNECT. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3758 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3759 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3760 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3761 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3762 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: When flashing a 2002 - 2004 LH vehicle the BCM may need to be disconnected if experiencing failures during the flash of the transmission portion of the PCM. The BCM will need to be disconnected after the module ID portion of the flash is complete. Before pressing Page Forward to begin the flash of the PCM Turn the Key to the OFF position and disconnect the BCM. Then turn the KEY to the RUN position and Press Page Forward to begin the PCM flash session. NOTE: If vehicle is a DAKOTA, then the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for any erroneous DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRB III(R) reboots to the MAIN MENU, proceed to Step 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3763 NOTE: If your vehicle is a 2002 LH and the original PCM part number begins with 04 the technician should use the 2002 LH Part Number Reference chart above to determine the corresponding "NEW" part number. This new number from the chart should then be entered into the Tech tools application as the original part number. If the original PCM number begins with 05 no change to the flash selection process is required. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the first ten (10) characters of the "PCM part # " on the repair order for later reference. NOTE: If the PCM is not operational, the part number can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step. 3. Page back to the "Main Menu" 4. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. 5. If the vehicle is not equipped with SKIM then proceed to step 6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with step 6. This information is available from one of the following: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. CAUTION: Failure to install the SKIM pin number into the module after flashing the PCM will cause a start and stall condition. 6. Replace the PCM using the appropriate generic control module. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E, Electronic Control Modules, Powertrain Control Module, Removal/Installation. 7. Open the hood, install a battery charger and verify battery state is above 11.5 volts. 8. If the old "PCM part # " is known, proceed to step 14. If the old "PCM part # " is not known, proceed to next step. 9. On DealerCONNECT select the "Service" tab. 10. Select "Vehicle Information Plus". 11. Manually enter the VIN and mileage and select "Enter". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3764 12. Select the "Vehicle Option" tab. 13. Under the "Vehicle Option window, identify and record: a. Engine. b. Emissions (Federal or California). c. Transmission (Automatic, 5-speed manual, etc.). 14. Connect the DRBIII(R) to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 15. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates. NOTE: Do NOT enter the generic controller part number in step 16a below. 16. Determine the proper calibration: a. If the old "PCM part # " is known, enter the part number of the old controller in the "Parts Criteria p/n window. Proceed to step 16. b. If the old "PCM part # " is not known, select the correct calibration based on the information that was recorded from "Vehicle Options" in step 13. 17. Select the correct calibration. 18. Select the "Download/Update button. 19. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII(R). When the flash process is completed, proceed to next step. 20. Enter the VIN in the PCM. Using the DRBIII® select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "Engine" e. "Miscellaneous" f. "Check VIN" g. If the vehicle is not equipped with SKIM proceed to step 20h. If the vehicle is equipped with SKIM follow the directions on the DRBIII(R). When the VIN and SKIM key has been programmed, proceed to step 20. h. Enter the VIN as requested by the DRBIII(R). 21. Update the PCM mileage. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Check PCM Odometer" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3765 g. "NO" h. Enter the current odometer mileage and then press "Enter". i. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter". 22. Proceed as follows: a. If the vehicle is equipped with an automatic transmission, proceed to step 24. b. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 24. c. If the vehicle is equipped with a Turbo engine and manual transmission, proceed to step 23. 23. On vehicles equipped with a Turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII® Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Pinion Factor" g. Select the correct tire size and then select "Page Back" to exit. h. Proceed to step 24. 24. On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Transmission" e. "Transmission Module" f. "Miscellaneous" g. "Pinion Factor" h. Select the correct tire size and then select "Page Back" to exit. i. Enter "Quick Learn" and then follow the instructions on the DRBIII(R). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3766 25. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3767 Engine Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3768 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3769 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 3770 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3771 Engine Control Module: Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views Powertrain Control Module C1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 3774 Powertrain Control Module C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 3775 Powertrain Control Module C3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 3776 Powertrain Control Module C4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 3777 Engine Control Module: Description and Operation Powertrain Control Module (PCM) The Powertrain Control Module (PCM) is a digital computer containing a microprocessor. The PCM receives input signals from various switches and sensors referred to as Powertrain Control Module Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices referred to as Powertrain Control Module Outputs. NOTE: PCM Inputs: - Air Conditioning Pressure Transducer - Ambient temperature Sensor - ASD Relay - Battery Temperature Sensor (NGC) - Battery Voltage - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Distance Sensor (from transmission control module) - EGR Position Feedback - Engine Coolant Temperature Sensor - Heated Oxygen Sensors - Ignition sense - Intake Air Temperature Sensor - Knock Sensor - Leak Detection Pump Feedback - Manifold Absolute Pressure (MAP) Sensor - Park/Neutral - PCI Bus - Power Steering Pressure Switch - Proportional Purge Sense - SCI Receive - Speed Control - Throttle Position Sensor - Transmission Control Relay (Switched B+) - Transmission Pressure Switches - Transmission Temperature Sensor - Transmission Input Shaft Speed Sensor - Transmission Output Shaft Speed Sensor - Transaxle Gear Engagement Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 3778 - Vehicle Speed NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Automatic Shut Down (ASD) and Fuel Pump Relays - Data Link Connector (PCI and SCI Transmit) - Double Start Override - EGR Solenoid - Fuel Injectors - Generator Field - High Speed Fan Relay - Idle Air Control Motor - Ignition Coils - Leak Detection Pump - Low Speed Fan Relay - MTV Actuator - Proportional Purge Solenoid - SRV Valve - Speed Control Relay - Speed Control Vent Relay - Speed Control Vacuum Relay - 8 Volt Output - 5 Volt Output - Torque Reduction Request - Transmission Control Relay - Transmission Solenoids - Vehicle Speed Based on inputs it receives, the powertrain control module (PCM) adjusts fuel injector pulse width, idle speed, ignition timing, and canister purge operation. The PCM regulates the cooling fans, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the generator field. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. - Battery Voltage - Intake Air Temperature Sensor - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Exhaust Gas Oxygen Content (heated oxygen sensors) - Manifold Absolute Pressure - Throttle Position The PCM adjusts engine idle speed through the idle air control motor based on the following inputs. - Brake Switch - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Park/Neutral - Transaxle Gear Engagement - Throttle Position - Vehicle Speed The PCM adjusts ignition timing based on the following inputs. - Intake Air Temperature - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Knock Sensor - Manifold Absolute Pressure - Park/Neutral - Transaxle Gear Engagement - Throttle Position The automatic shut down (ASD) and fuel pump relays are mounted externally, but turned on and off by the powertrain control module through the same circuit. The camshaft and crankshaft signals are sent to the powertrain control module. If the PCM does not receive both signals within approximately one second of engine cranking, it deactivates the ASD and fuel pump relays. When these relays are deactivated, power is shut off to the fuel injectors, ignition coils, fuel pump and the heating element in each oxygen sensor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 3779 The PCM contains a voltage converter that changes battery voltage to a regulated 8.0 volts. The 8.0 volts power the camshaft position sensor, crankshaft position sensor and vehicle speed sensor. The PCM also provides a 5.0 volts supply for the engine coolant temperature sensor, intake air temperature sensor, manifold absolute pressure sensor and throttle position sensor. The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage in new PCM. Use the DRBIII(R) scan tool to change the mileage in the PCM. TRANSMISSION CONTROL CLUTCH VOLUME INDEX (CVI) Example Of CVI Calculation An important function of the PCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The PCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the PCM that represents input shaft rpm. The Output Speed Sensor provides the PCM with output shaft speed information. By comparing the two inputs, the PCM can determine transaxle gear ratio. This is important to the CVI calculation because the PCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the PCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the PCM can determine the volume of fluid used to apply or release a friction element. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 3780 The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: SHIFT SCHEDULES As mentioned earlier, the PCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Part 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 3781 Part 2 As driving conditions change, the PCM appropriately adjusts the shift schedule. Refer to the chart to determine the appropriate operation expected, depending on driving conditions. SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). DATA BUS COMMUNICATION RECEIVE - PCM INPUT The PCM uses the SCI communication bus to preform engine diagnostics and flash operations. The transmission side of the PCM uses the SCI communication bus to flash new software. However, diagnostics is performed via the vehicles J1850 bus for the transmission side of the PCM. IGNITION SENSE - PCM INPUT The ignition sense input informs the Powertrain Control Module (PCM) that the ignition switch is in the crank or run position. PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded separately from the ground pins. 5 VOLT SUPPLY - PCM OUTPUT The PCM supplies 5 volts to the following sensors: - A/C pressure transducer - Ambient Temperature sensor - Battery temperature - Camshaft Position Sensor (NGC) - Crankshaft Position Sensor (NGC) - Engine coolant temperature sensor - Inlet Air Temperature Sensor - Knock sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 3782 - Linear EGR solenoid (if equipped) - Manifold absolute pressure sensor - Oil Pressure Switch - Throttle position sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming Engine Control Module: Service and Repair PCM/SKIM Programming NOTE: Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. When a PCM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new PCM. 2. Program the new SKIM. 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE PCM The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the scan tool. Perform the following steps to program the secret key into the PCM. 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Enter secured access mode by entering the vehicle four-digit PIN. 5. Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 6. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). 7. Press Page Back to get to the Select System menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK. 8. The scan tool will ask, Is odometer reading between XX and XX? Select the YES or NO button on the scan tool. If NO is selected, the scan tool will read, Enter odometer Reading. Enter the odometer reading from the Instrument Panel and press ENTER. PROGRAMMING THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Program the vehicle four-digit PIN into SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. 6. Select YES to update VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the secret key (the PCM will send the secret key to the SKIM). 8. Program ignition keys to SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEY'S. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following messages: Programming Not Attempted The scan tool attempts to read the programmed key status and there are no keys programmed into SKIM memory. Programming Key Failed (Possible Used Key From Wrong Vehicle) SKIM is unable to program key due to one of the following: - faulty ignition key transponder - ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming > Page 3785 - SKIM transponder ID memory is full. 5. Obtain ignition keys to be programmed from customer (8 keys maximum). 6. Using the scan tool, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN. KEYS. 7. Program all ignition keys. Learned Key In Ignition Ignition key transponder ID is currently programmed in SKIM memory. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming > Page 3786 Engine Control Module: Service and Repair Powertrain Control Module SBEC Controller REMOVAL 1. Disconnect the negative battery cable. 2. Remove the battery shield. PCM 3. Remove the 2 upper PCM bracket bolts. 4. Remove the 2 PCM connectors. 5. Remove the headlamp PCM Lower Bolt 6. Remove the lower PCM mounting bolt. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming > Page 3787 7. Remove PCM. INSTALLATION 1. Install the PCM. 2. Install the lower PCM mounting bolt. Tighten bolt. 3. Install the 2 upper PCM bracket bolts. Tighten bolt. 4. Install the headlamp. 5. Install the 2 PCM connectors. 6. Install the battery shield. 7. Connect the negative battery cable. NGC Controller REMOVAL NGC Controller Location The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage and vehicle identification number (VIN) in the new PCM. Use the DRBIII(R) scan tool to change the millage and VIN in the PCM. If this step is not done a Diagnostic Trouble Code (DTC) may be set. 1. Turn wheels to the left. 2. Disconnect the negative battery cable. 3. Raise vehicle and support. Splash Shield Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming > Page 3788 4. Remove the left front wheel well splash shield. NGC Controller 5. Unlock and disconnect the electrical connectors. 6. Remove 3 screws from PCM to mounting bracket. 7. Remove the PCM. INSTALLATION The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage and vehicle identification number (VIN) in the new PCM. Use the DRBIII(R) scan tool to change the millage and VIN in the PCM. If this step is not done a diagnostic trouble code (DTC) may be set and SKIM must be done or car will not start if it is a SKIM equipped car. If a SKIM car you must do a secret key transfer also. 1. Install PCM module to the mounting bracket. 2. Install electrical connectors and lock. 3. Install the splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. 6. Using DRBIII(R) scan tool, program mileage and vehicle identification number (VIN) into PCM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Pump Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3792 Fuel Level Sensor: Service and Repair Fuel Pump/Level Sensor Electrical Connector Wire Terminal Locking Finger Removing Wires From Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3793 Loosening Level Sensor Level Sensor Removal/Installation Groove In Back Side Of Level Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3794 Installation Channel Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations > Page 3799 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 3800 Idel Air Control Motor (GAS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 3801 Idle Speed/Throttle Actuator - Electronic: Description and Operation TPS/IAC 2.4L TPS/IAC 3.3/3.8L The idle air control motor is mounted on the throttle body. The PCM operates the idle air control valve. The PCM adjusts engine idle speed through the idle air control motor to compensate for engine load, coolant temperature or barometric pressure changes. The throttle body has an air bypass passage that provides air for the engine during closed throttle idle. The idle air control motor pintle protrudes into the air bypass passage. The PCM controls engine idle speed by adjusting the position of the idle air control valve. The adjustments are based on inputs the PCM receives. The inputs are from the throttle position sensor, crankshaft position sensor, coolant temperature sensor, MAP sensor, vehicle speed sensor and various switch operations (brake, park/neutral, air conditioning). When engine rpm is above idle speed, the IAC is used for the following functions: - Off-idle dashpot - Deceleration air flow control Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 3802 - A/C compressor load control (also opens the passage slightly before the compressor is engaged so that the engine rpm does not dip down when the compressor engages). Target Idle Target idle is determined by the following inputs: - Gear position - ECT Sensor - Battery voltage - Ambient/Battery Temperature Sensor - VSS - TPS - MAP Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 3803 Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL When servicing throttle body components, always reassemble components with new 0-rings and seals where applicable. If assembly of component is difficult, a light coat of engine oil may be applied to the 0-RINGS ONLY to aid assembly. Use care when removing hoses to prevent damage to hose or hose nipple. 1. Disconnect negative cable from battery. Idle Air Control Valve Location 2. Remove electrical connector from idle air control valve. 3. Remove idle air control motor mounting screws. 4. Remove motor from throttle body. Ensure the O-rings is removed with the valve. INSTALLATION O - Rings When servicing throttle body components, always reassemble components with new O-rings and seals where applicable. Never use lubricants on O-rings or seals, damage may result. If assembly of component is difficult, a light coat of engine oil may be applied to the O-RINGS ONLY to aid assembly. Use care when removing hoses to prevent damage to hose or hose nipple. 1. Carefully place idle air control motor into throttle body. 2. Install mounting screw. Tighten screws to 7 N.m (62 in. lbs.) torque. 3. Connect electrical connector to idle air control motor. 4. Connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3808 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3809 Figure 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3810 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3811 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3812 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3813 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3814 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3815 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3816 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3817 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3818 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3819 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3820 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3821 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3822 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3823 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3824 Information Bus: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and an Electrostatic Discharge Symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3825 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3826 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3827 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3828 Information Bus: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-18-2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3829 8w-18-3 (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3830 8w-18-5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3831 8w-18-6 Other Diagrams: Other diagrams referred to by number (i.e 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 3832 Information Bus: Description and Operation The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25 and is white with a violet tracer. Additional tracer colors may be added to the violet in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on the RS/RG: - Body Control Module - Front Control Module - Occupant Restraint Controller - Occupant Classification Module - Controller Antilock Brake (MK20E) - Antilock Brake Module (MK25E) - Powertrain Control Module (Gas) - Transmission Control Module (Diesel Auto Only) - Engine Control Module (Diesel) - Radio - Amplifier - CD Changer - DVD/CD Changer - Hands Free Module - Automatic Temperature Control Module - A/C Heater Control Module (MTC) - Sentry Key Remote Entry Module (SKREEM) - Memory Seat/Mirror/Adjustable Pedals Module (MSMAPM) - Overhead Console - Mechanical Instrument Cluster - Left Sliding Door Control Module - Right Sliding Door Control Module - Thatcham Alarm Module (Export) - Power Liftgate Module - Park Assist Module Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRBIII(R) lab scope. The 12 v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open PCI circuit at the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: - All gauges on the MIC stay at zero - All telltales on MIC illuminate - MIC backlighting at full intensity - Dashed lines in the overhead console ambient temperature display - No response received from any module on the PCI bus (except the PCM/ECM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRBIII(R). Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRBIII(R) If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRBIII(R) may display BUS ± SIGNAL OPEN or NO RESPONSE to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRBIII(R) and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. NOTE: For 2005 model year, some vehicles will integrate the Transmission Control Module and Powertrain Control Module into a single control module. This new module is the Next Generation Controller for DaimlerChrysler and will be referred to as the Powertrain Control Module (PCM). The Transmission Control Module is part of the Powertrain Control Module. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 3833 Diagnostic procedures and DTC numbers are some of the changes you will see which reflect the new combined module technology. The PCM will have four color coded connectors C1 through C4, (C1-BLK, C2-ORANGE, C3-WHITE, C4-GREEN), each PCM connector will have 38 pins each. Two new tools are used for probing and repairing the New PCM connectors. A New tool to release the pins from the PCM connectors Miller #3638 is introduced, you must use the Miller tool #3638 to release the connector pins or harness and connector damage will occur. Also a New tool for probing connectors Miller #8815 is introduced, you must use the Miller tool #8815 to probe the PCM pins or harness and connector damage will occur. There is also a new Verification test and module replacement procedure for the PCM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation The knock sensor threads into the cylinder block. The knock sensor is designed to detect engine vibration that is caused by detonation. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives as an input the knock sensor voltage signal. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except WOT. The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3840 Main Relay (Computer/Fuel System): Diagrams Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3841 Auto Shut Down Relay Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3842 Main Relay (Computer/Fuel System): Description and Operation AUTO SHUT DOWN RELAY The relay is located in the Power Distribution Center (PDC). For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary The engine switched battery (NGC vehicles) informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is also used to power certain drivers on NGC vehicles. When energized, the ASD relay on NGC vehicles provides power to operate the injectors, ignition coil, generator field, O2 sensor heaters (both upstream and downstream), evaporative purge solenoid, EGR solenoid (if equipped) wastegate solenoid (if equipped), and NVLD solenoid (if equipped). The ASD relay also provides a sense circuit to the PCM for diagnostic purposes. If the PCM does not receive 12 volts from this input after grounding the control side of the ASD relay, it sets a Diagnostic Trouble Code (DTC). The PCM energizes the ASD any time there is an engine speed that exceeds a predetermined value (typically about 50 rpm). The ASD relay can also be energized after the engine has been turned off to perform an O2 sensor heater test, if vehicle is equipped with OBD II diagnostics. As mentioned earlier, the PCM energizes the ASD relay during an O2 sensor heater test. On NGC vehicles it checks the O2 heater upon vehicle start. The PCM still operates internally to perform several checks, including monitoring the O2 sensor heaters. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3846 Manifold Absolute Pressure Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3847 Manifold Pressure/Vacuum Sensor: Description and Operation Map Sensor 2.4L Map Sensor 3.3/3.8L The MAP sensor mounts to the intake manifold The sensor is connects electrically to the PCM The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a volt-age signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5 V and full scale is 4.5 V. For a pressure swing of 0 - 15 psi the voltage changes 4.O V. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key on. The difference between current and what it was at key on is manifold vacuum. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3848 During key On (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in you work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key On the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC 1 transmissions only via the PCI bus) - Idle speed - Decel fuel shutoff The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 29.92 in Hg. For every 100 feet of altitude barometric pressure drops .10 in. Hg. If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3849 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. Map Sensor 3.3/3.8L 2. Remove vacuum hose and mounting screws from manifold absolute pressure (MAP) sensor. 3. Disconnect electrical connector from sensor. Remove sensor. INSTALLATION 1. Install sensor. 2. Install screws and tighten to PLASTIC MANIFOLD 1.7 N.m (15 in. lbs.) ALUMINUM MANIFOLD 3.3 N.m (30 in. lbs.). 3. Connect the electrical connector to the sensor. Install vacuum hose. 4. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Oxygen Sensors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 3853 3.3-3.8 Liter Engine Front Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 3854 Engine Pressure Switch (GAS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC P0135 Set NUMBER: 18-010-05 REV. A GROUP: Vehicle Performance DATE: March 4, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-010-05, DATED FEBRUARY 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN UPDATED VEHICLE BUILD DATE. THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD APRIL, 2005. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DIG) P0135 - 02 Sensor 1/1 Heater Performance OVERVIEW: This bulletin involves verifying the proper 1/1 02 Sensor is installed on the vehicle and reprogramming the Powertrain Control Module with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager NOTE: **This bulletin applies to 2005 CS and RS vehicles equipped with a 3.8L engine (sales code EGH) built on and between July 8, 2004 (MDH 0708XX) and March 2, 2005 (MDH 0302XX). 2005 RS vehicles equipped with a 3.3L engine (sales code EGA, EGM and EGH) built on and between July 8, 2004 (MDH 0708XX) and October 29, 2004 (MDH 1029XX).** SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by the following Diagnostic Trouble Codes (DTC's): P0135 - 02 Sensor 1/1 Heater Performance DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than the one listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. Verify that the correct 02 Sensor is installed on the vehicle. Refer to Service Bulletin 08-008-05. Installing an incorrect 1/1 02 sensor will cause a MIL illumination for DTC P0135 - 02 Sensor 1/1 Heater Performance to be set. If the vehicle operator describes or experiences the Symptom/Condition and the correct 1/1 02 sensor is installed on the vehicle, perform the Repair Procedure. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 3863 SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 3864 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 08-008-05 > Feb > 05 > Engine Controls - MIL ON/DTC P0135 (O2 Sensor) Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC P0135 (O2 Sensor) NUMBER: 08-008-05 GROUP: Electrical DATE: February 4, 2005 SUBJECT: 1/1 02 Sensor Usage MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager 2005 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to 2005 CS vehicles equipped with a 3.8L engine (sales code EGH), 2005 RS or 2005 RG vehicles equipped with a 3.313.8L engine (sales code EGA, EGM and EGH). DISCUSSION: A new 1/1 02 sensor (PN 56029085AA) has been introduced on the 3.313.8L engines for the 2005 RS/RG and CS vehicles built after July 8, 2004 (MDH 0708XX). Installing an incorrect 1/1 02 sensor will cause a MIL illumination for DTC P0135 - 02 Sensor 1/1 Heater Performance to be set. The operation of the new 02 sensor has also changed. The new 1/1 02 sensor runs at 100% duty cycle all the time because the resistance of the heater is higher. Monitoring the 1/1 02 sensor with the DRBIII(R) while the vehicle is in the service bay will show 100% duty cycle, which is normal for this new sensor. 2005 Model Year 1/1 02 Sensor Usage POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0135 Set NUMBER: 18-010-05 REV. A GROUP: Vehicle Performance DATE: March 4, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-010-05, DATED FEBRUARY 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN UPDATED VEHICLE BUILD DATE. THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD APRIL, 2005. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DIG) P0135 - 02 Sensor 1/1 Heater Performance OVERVIEW: This bulletin involves verifying the proper 1/1 02 Sensor is installed on the vehicle and reprogramming the Powertrain Control Module with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager NOTE: **This bulletin applies to 2005 CS and RS vehicles equipped with a 3.8L engine (sales code EGH) built on and between July 8, 2004 (MDH 0708XX) and March 2, 2005 (MDH 0302XX). 2005 RS vehicles equipped with a 3.3L engine (sales code EGA, EGM and EGH) built on and between July 8, 2004 (MDH 0708XX) and October 29, 2004 (MDH 1029XX).** SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by the following Diagnostic Trouble Codes (DTC's): P0135 - 02 Sensor 1/1 Heater Performance DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than the one listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. Verify that the correct 02 Sensor is installed on the vehicle. Refer to Service Bulletin 08-008-05. Installing an incorrect 1/1 02 sensor will cause a MIL illumination for DTC P0135 - 02 Sensor 1/1 Heater Performance to be set. If the vehicle operator describes or experiences the Symptom/Condition and the correct 1/1 02 sensor is installed on the vehicle, perform the Repair Procedure. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 3874 SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 3875 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 08-008-05 > Feb > 05 > Engine Controls - MIL ON/DTC P0135 (O2 Sensor) Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0135 (O2 Sensor) NUMBER: 08-008-05 GROUP: Electrical DATE: February 4, 2005 SUBJECT: 1/1 02 Sensor Usage MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager 2005 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to 2005 CS vehicles equipped with a 3.8L engine (sales code EGH), 2005 RS or 2005 RG vehicles equipped with a 3.313.8L engine (sales code EGA, EGM and EGH). DISCUSSION: A new 1/1 02 sensor (PN 56029085AA) has been introduced on the 3.313.8L engines for the 2005 RS/RG and CS vehicles built after July 8, 2004 (MDH 0708XX). Installing an incorrect 1/1 02 sensor will cause a MIL illumination for DTC P0135 - 02 Sensor 1/1 Heater Performance to be set. The operation of the new 02 sensor has also changed. The new 1/1 02 sensor runs at 100% duty cycle all the time because the resistance of the heater is higher. Monitoring the 1/1 02 sensor with the DRBIII(R) while the vehicle is in the service bay will show 100% duty cycle, which is normal for this new sensor. 2005 Model Year 1/1 02 Sensor Usage POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3882 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3883 Oxygen Sensor: Connector Locations Oxygen Sensors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3884 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 3885 3.3-3.8 Liter Engine Front Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3886 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream (3.3L/3.8L) Oxygen Sensor 1/2 Downstream (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3887 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3888 Oxygen Sensor: Description and Operation O2 Sensor Upstream 1/1 - 2.4L O2 Sensor Upstream 1/1 - 3.3/3.8L The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3889 O2 Sensor Downstream 1/2 - 2.4/3.3/3.8L The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic convertor. A separate upstream and downstream grounds are used on the NGC vehicles (4 Cyl). As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor, one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The 02 sensors produce a constant 2.5 volts on NGC vehicles, depending upon the oxygen content of the exhaust gas. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produces a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2 sensors input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. NGC Controller - Has a common ground for the heater in the 02S. 12 volts is supplied to the heater in the 02S by the NGC controller. Both the upstream and downstream 02 sensors for NGC are pulse width modulation (PWM). NOTE: When replacing an 02 Sensor, the PCM RAM memory must be cleared, either by disconnecting the PCM C-1 connector or momentarily disconnecting the Battery negative terminal. The NGC learns the characteristics of each O2 heater element and these old values should be cleared when installing a new 02 sensor. The customer may experience driveability issues if this is not performed. UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 2.5 to 3.5 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 2.5 volt. When there is a lesser amount of oxygen present (rich air/fuel mixture) the sensor produces a voltage as high as 3.5 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3890 The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. DOWNSTREAM OXYGEN SENSOR The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. Also used to establish the upstream 02 goal voltage (switching point). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor REMOVAL - DOWNSTREAM 1/2 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Downstream Oxygen Sensor (1/2) 3. Disconnect the electrical connector. Downstream 2/1 O2 Sensor 4. Use a socket such as the Snap-On(R) YA8875 or equivalent to remove the sensor. 5. When the sensor is removed, the threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using the original sensor, coat the threads with Loctite 771 - 64 anti-seize compound or equivalent. INSTALLATION - DOWNSTREAM 2/1 The O2S is located on the side of the catalytic converter. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 3893 Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install sensor and tighten to 27 N.m (20 ft. lbs.). 2. Connect the electrical connector. 3. Lower vehicle. 4. Install the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 3894 Oxygen Sensor: Service and Repair Upstream Sensor REMOVAL - UPSTREAM 1/1 1. Remove battery, refer to the Battery section for more information. 2. Remove the battery tray, refer to the Battery section for more information. 3. Disconnect the speed control vacuum harness from servo. 4. Disconnect the electrical connector from servo. 5. Remove the speed control servo and bracket and reposition. O2 Sensor 1/1 6. Use a socket such as the Snap-On(R) YA8875 or equivalent to remove the sensor. 7. When the sensor is removed, the threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using the original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. INSTALLATION - UPSTREAM 1/1 The engines uses two heated oxygen sensors. 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771 - 64 or equivalent. New sensors have compound on the threads and do not require an additional coating. 2. Install sensor and tighten to 27 N.m (20 ft. lbs.). 3. Connect the electrical connector for the O2 sensor and install onto bracket. 4. Connect the electrical connector for the speed control servo. 5. Install the speed control servo and bracket refer to the Speed Control Servo for more information. 6. Connect the speed control vacuum harness to servo. 7. Install the battery tray, refer to the Battery section for more information. 8. Install battery, refer to the Battery section for more information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 3895 Oxygen Sensor: Tools and Equipment O2S (Oxygen Sensor) Removal/Install - C 4907 O2S (Oxygen Sensor) Removal/Install - 8439 O2S (Oxygen Sensor) Removal/Installation C 4907 O2S (Oxygen Sensor) Removal/Installer - 8439 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set Body Control Module: Customer Interest Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set NUMBER: 08-028-05 GROUP: Electrical DATE: May 28, 2005 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD JULY, 2005. SUBJECT: Flash: MIL Illumination, Remote Keyless Entry (RKE) Inoperative OVERVIEW: This bulletin involves reprogramming the Body Control Module (BCM) with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to CS vehicles built on or before May 7, 2005 (MDH 0507XX) and RS vehicles, built on or between July 26, 2004 (MDH 0726XX) through and including May 7, 2005 (MDH 0507XX), with a 4-connector BCM. SYMPTOM/CONDITION: ^ MIL Illumination ^ RKE inoperative ^ PCI Internal Fault DTC in BCM DIAGNOSIS: 1. With the ignition switch in the "RUN" position, determine the original software part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R)" standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 3905 g. Record the "Software part # " on the repair order for later reference. h. Check DTC's 2. If the Symptom/Condition is present, use the following table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "BCM part # ", recorded in "Diagnosis Step # 1, in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 4. Select the flash file. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 3906 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm Body Control Module: Customer Interest Electrical - Locks Inoperative/Liftgate Triggers Alarm NUMBER: 08-040-04 GROUP: Electrical DATE: December 9, 2004 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD FEBRUARY, 2005. SUBJECT: Flash: Driver And Passenger Power Door Lock Switches Inoperative And Opening the Liftgate Triggers The Theft Alarm OVERVIEW: This bulletin involves selectively erasing and reprogramming the Body Control Module (BCM) with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to 2005 vehicles equipped with Power Locks only (sales code JPB) and 2004 2005 vehicles equipped with Power Locks, Power Liftgate, and Security Alarm (sales codes JPB, JRC and LSA respectively). SYMPTOM/CONDITION: The vehicle operator may describe: ^ The alarm sounds erroneously when opening the power liftgate using the key fob while the Vehicle Theft Alarm (VTA) is armed. ^ The driver's and/or passenger's door lock switches are inoperative. The technician may find "Left Unlock Output Failure" and/or "Right Unlock Output Failure" Diagnostic Trouble Codes (DTC's) in the BCM. DIAGNOSIS: 1. Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. With the ignition switch in the "RUN" position, determine the original part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" g. Record the "Software part # " on the repair order for later reference. h. Check DTC's Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm > Page 3911 3. If the vehicle operator describes or experiences the Symptom/Condition, use the table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "Software part # " recorded during "Diagnosis" in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 4. Select the calibration. 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm > Page 3912 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition to the "Run" position (engine not running). 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. 13. Verify that the problem cannot be repeated by cycling the ignition switch OFF/ON and actuating both door lock switches a few times. If any door lock failure still persists then further diagnosis is necessary. Verify the BCM "Software p/n" was updated to the new software p/n using Diagnosis Step # 2. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, PCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set Body Control Module: All Technical Service Bulletins Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set NUMBER: 08-028-05 GROUP: Electrical DATE: May 28, 2005 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD JULY, 2005. SUBJECT: Flash: MIL Illumination, Remote Keyless Entry (RKE) Inoperative OVERVIEW: This bulletin involves reprogramming the Body Control Module (BCM) with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to CS vehicles built on or before May 7, 2005 (MDH 0507XX) and RS vehicles, built on or between July 26, 2004 (MDH 0726XX) through and including May 7, 2005 (MDH 0507XX), with a 4-connector BCM. SYMPTOM/CONDITION: ^ MIL Illumination ^ RKE inoperative ^ PCI Internal Fault DTC in BCM DIAGNOSIS: 1. With the ignition switch in the "RUN" position, determine the original software part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R)" standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 3918 g. Record the "Software part # " on the repair order for later reference. h. Check DTC's 2. If the Symptom/Condition is present, use the following table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "BCM part # ", recorded in "Diagnosis Step # 1, in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 4. Select the flash file. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 3919 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm Body Control Module: All Technical Service Bulletins Electrical - Locks Inoperative/Liftgate Triggers Alarm NUMBER: 08-040-04 GROUP: Electrical DATE: December 9, 2004 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD FEBRUARY, 2005. SUBJECT: Flash: Driver And Passenger Power Door Lock Switches Inoperative And Opening the Liftgate Triggers The Theft Alarm OVERVIEW: This bulletin involves selectively erasing and reprogramming the Body Control Module (BCM) with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to 2005 vehicles equipped with Power Locks only (sales code JPB) and 2004 2005 vehicles equipped with Power Locks, Power Liftgate, and Security Alarm (sales codes JPB, JRC and LSA respectively). SYMPTOM/CONDITION: The vehicle operator may describe: ^ The alarm sounds erroneously when opening the power liftgate using the key fob while the Vehicle Theft Alarm (VTA) is armed. ^ The driver's and/or passenger's door lock switches are inoperative. The technician may find "Left Unlock Output Failure" and/or "Right Unlock Output Failure" Diagnostic Trouble Codes (DTC's) in the BCM. DIAGNOSIS: 1. Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. With the ignition switch in the "RUN" position, determine the original part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" g. Record the "Software part # " on the repair order for later reference. h. Check DTC's Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm > Page 3924 3. If the vehicle operator describes or experiences the Symptom/Condition, use the table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "Software part # " recorded during "Diagnosis" in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 4. Select the calibration. 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm > Page 3925 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition to the "Run" position (engine not running). 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. 13. Verify that the problem cannot be repeated by cycling the ignition switch OFF/ON and actuating both door lock switches a few times. If any door lock failure still persists then further diagnosis is necessary. Verify the BCM "Software p/n" was updated to the new software p/n using Diagnosis Step # 2. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, PCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 3928 Body Control Module: Connector Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 3929 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 3930 Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3933 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3934 Figure 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3935 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3936 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3937 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3938 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3939 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3940 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3941 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3942 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3943 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3944 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3945 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3946 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3947 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3948 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3949 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and an Electrostatic Discharge Symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3950 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3951 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3952 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3953 Body Control Module: Connector Views Body Control Module C1 Body Control Module C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3954 Body Control Module C3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3955 Body Control Module C4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3956 Body Control Module C5 (early Build) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3957 Body Control Module: Electrical Diagrams Non-memory Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3958 Memory Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3959 Occupant Restraint Controller - Highline Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3960 Occupant Restraint Controller - Lowline Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3961 Occupant Classification System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3962 Premium Audio System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3963 Base Audio System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3964 CD Changer DVD/CD Changer Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3965 Remote Radio Controls Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3966 Front ATC - LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3967 Front ATC - RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3968 Rear ATC - Three Zone Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3969 Diesel Cabin Heater Assist (DCHA) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3970 Communication Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3971 PCM Communication - NGC ECM And Cabin Heater Assist Communication - Diesel Only Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3972 Door Ajar System With Power Sliding Doors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3973 Door Ajar System Without Power Sliding Doors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3974 Exterior Lighting Horn System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3975 Ignition Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3976 Integrated Power Module/body Control Module Power And Grounds Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3977 Instrument Cluster - Base Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3978 Instrument Cluster And Message Center (export, LHD) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3979 Instrument Cluster And Message Center (export,RHD) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3980 Interior Lighting Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3981 Base Manual Temperature Control System, LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3982 Base Manual Temperature Control System. RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3983 Dual-zone And Three Zone(front) Manual Temperature Control System, LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3984 Dual-zone Zone(front) Manual Temperature Control System, RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3985 Three Zone Rear Manual Temperature Control System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3986 Front Blower Motor - RS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3987 Front Blower Motor - RG Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3988 Rear Blower Motor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3989 Memory System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3990 Overhead Console Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3991 Park Assist Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3992 Power Door Looks/RKE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3993 LHD (export Only) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3994 RHD (export Only) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3995 Power Liftgate System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3996 Lift Power Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3997 Right Power Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3998 Power Sliding Door And Liftgate Switches Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3999 Rear Defog/Heated Mirror Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4000 Hands Free Phone - With CD Changer Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4001 Hands Free Phone - With CD/DVD Changer Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4002 Vehicle Theft Security System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4003 Thatcam Alarm System (export Only) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4004 Wipers - Front And Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4005 A/C - Lef Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4006 Le - Tr 8W-45-2 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4007 8w-45-2 Next Diagram See: 8W-45-3 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-3 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4008 8w-45-3 Next Diagram See: 8W-45-4 Previous Diagram See: 8W-45-2 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4009 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-4 Next Diagram See: 8W-45-5 Previous Diagram See: 8W-45-3 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4010 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-5 Next Diagram See: 8W-45-6 Previous Diagram See: 8W-45-4 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4011 8W-45-6 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-6 Next Diagram See: 8W-45-7 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4012 Previous Diagram See: 8W-45-5 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-7 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4013 8w-45-7 Next Diagram See: 8W-45-8 Previous Diagram See: 8W-45-6 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-8 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4014 8w-45-8 Next Diagram See: 8W-45-9 Previous Diagram See: 8W-45-7 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4015 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-9 Next Diagram See: 8W-45-10 Previous Diagram See: 8W-45-8 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4016 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-10 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4017 Next Diagram See: 8W-45-11 Previous Diagram See: 8W-45-9 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-11 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4018 8w-45-11 Next Diagram See: 8W-45-12 Previous Diagram See: 8W-45-10 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-12 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4019 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-12 Next Diagram See: 8W-45-13 Previous Diagram See: 8W-45-11 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4020 Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-13 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-13 Next Diagram See: 8W-45-14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4021 Previous Diagram See: 8W-45-12 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-14 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4022 8w-45-14 Next Diagram See: 8W-45-15 Previous Diagram See: 8W-45-13 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4023 8W-45-15 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-15 Next Diagram See: 8W-45-16 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4024 Previous Diagram See: 8W-45-14 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-16 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4025 8w-45-16 Next Diagram See: 8W-45-17 Previous Diagram See: 8W-45-15 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-17 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4026 8w-45-17 Next Diagram See: 8W-45-18 Previous Diagram See: 8W-45-16 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-18 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-18 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4027 Next Diagram See: 8W-45-19 Previous Diagram See: 8W-45-17 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-19 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4028 8w-45-19 Next Diagram See: 8W-45-20 Previous Diagram See: 8W-45-18 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-20 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4029 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-19 Previous Diagram See: 8W-45-19 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4030 Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced as an assembly only. Attempting to remove or repair certain system subcomponents may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 4033 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description Body Control Module: Description and Operation System Description IDENTIFICATION OF SYSTEM The vehicle systems that are part of the body system are: - Adjustable Pedal System (APS) - Airbag System - Audio - Automatic Temperature Control - Cabin Heater - Chime - Communication - Door Ajar System - Electrically heated system - Exterior lighting - Instrument Cluster - Interior Lighting - Manual Temperature Control - Memory Seat - Overhead Console - Park Assist - Power Door Lock/RKE - Power Folding Mirrors - Power Sliding Doors - Power Liftgate - Power windows - Telecommunications (hands free phone) - Tire Pressure Monitor System (TPMS) - Vehicle Theft Security System (VTSS) - Windshield Wiper and Washer SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 2005 RS and RG consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate modules. All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages addressed to it through binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the Communication Section of this general information. The Body Control Module (BCM) is located in the passenger compartment, attached to the bulkhead underneath the left side of the instrument panel. The BCM utilizes integrated circuitry and information carried on the Programmable Communications Interface (PCI) data bus network along with many hard wired inputs to monitor many sensor and switch inputs throughout the vehicle. In response to those inputs, the internal circuitry and programming of the BCM allow it to control and integrate many electronic functions and features of the vehicle through both hard wired outputs and the transmission of electronic message outputs to other electronic modules in the vehicle over the PCI data bus. The Body Control Module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the BCM is interfaced to the vehicle's serial bus communications network, referred to as the Programmable Communications Interface (PCI) bus. This network consists of the; - Powertrain Control Module (PCM) - Transmission Control Module (TCM) - Mechanical Instrument Cluster (MIC) - Occupant Restraint Controller (ORC) - Compass/Mini-Trip Computer (CMTC) - Electronic Vehicle Information Center (EVIC) - Controller Antilock Brake (CAB) - HVAC Control Module - Sliding Door Control Modules (driver and passenger side doors) - Power Liftgate Module (PLG) - Audio system equipped with RAZ, RBU, RBK, and RBB radios. - Sentry Key Remote Entry Module (SKREEM). - Side Impact Airbag Control Module (SIACM) - Memory Seat Module (MSM) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4036 - Sentry Key Immobilizer Module (SKIM) The BCM is operational when battery power is supplied to the module. The BCM provides the following features: - Power Door Locks - Automatic Door Locks - Battery Protection - The BCM will automatically turn off all exterior lamps after 3 minutes, and all interior lamps after 15 minutes after the ignition is turned off, if they are not turned off by the driver. - Chime Control - Compass/Mini-Trip support. - Interior Lighting (Courtesy/Reading Lamps) - BCM Diagnostic Reporting - Electronic Liftgate Release (with Power Door Locks) - Exterior Lighting - Headlamp Time Delay (with/without Automatic Headlamps) - Illuminated Entry - Fade to Off Interior Lamps - This feature dims the interior lighting (courtesy lamps) gradually if the BCM does not receive any new inputs that would cause the interior lamps to remain on. - Pulse Width Modulated Instrument Panel Dimming - Door Lock Inhibit - This feature disables the door lock functions if the key is in the ignition and either front door is ajar. Pressing the Remote Keyless Entry (RKE) lock/unlock button under these conditions result in normal lock/unlock activation. Learned Features The BCM has the ability to LEARN additional features in the vehicle, provided the appropriate switch input and PCI data bus messages are received. Refer to the LEARNED FEATURES table. When replacing a BCM there are three modules available: - Base - Midline - RG - Export Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4037 The Midline controller is used on vehicles that have Power Door Locks. If a vehicle is equipped with the Vehicle Theft Security System, the Midline controller becomes a Premium when the theft feature is enabled. CAUTION: Do not swap Body Control Modules between vehicles or body controller's off the shelf. The BCM has internal diagnostic capability that assists in diagnosing the system error. When an OPEN or a SHORT circuit exists, the diagnostic tool can be used to read the BCM faults. The faults are very descriptive in identifying the appropriate feature that has faulted. The only two faults that the BCM logs that conclude the replacement of a BCM are faults; - # 01 - Internal BCM failure (replace BCM) - # 1F - J1850 Internal Hardware Failure (replace BCM) Otherwise the appropriate diagnostic procedures for each of the features should be taken when the BCM logs a fault. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4038 Body Control Module: Description and Operation Functional Operation Adjustable Pedals System The Adjustable Pedals are designed to enable the fore and aft repositioning of the brake and accelerator pedals. This results in improved ergonomics in relation to the steering wheel for taller and shorter drivers. Being able to adjust the pedal positions also allows the driver to set steering wheel tilt and seat positions to the most comfortable position available. The positions can be adjusted without compromising safety or comfort in actuating the pedals. Repositioning the pedals does not change the effort required for actuation. Changing of pedal position is accomplished by means of a motor. Operating the adjustable pedal switch activates the pedal drive motor. The pedal drive motor changes the position of the brake and accelerator pedals. The pedal can move rearward or forward. The pedals are moved to a position that is most comfortable for the driver. The accelerator and brake pedals are moved at the same rate to ensure synchronization. Neither the motor nor mechanisms are subject to mechanical stress of brake or accelerator application. The adjustable pedals feature is available on a non-memory/memory-equipped vehicle. The non-memory system consists of a mechanical switch that allows pedal travel adjustment. The IPM controls the Fused B+ circuit voltage to the adjustable pedals switch through the adjustable pedals relay. The circuit opens when the IPM detects an active cruise control state or when the vehicle is in reverse. The adjustable pedals control switch is located on the right side steering column shroud. The switch is hardwired directly to the adjustable pedals motor. When the operator actuates the switch to adjust the pedals, voltage is applied to the adjustable pedals motor allowing adjustment. The memory system, known as the Memory Seat Mirror Adjustable Pedal Module (MSMAPM), is located under the driver's seat and controls the adjustable pedals. The adjustable pedals control switch is located on the right side steering column shroud. The switch is hardwired directly to the MSMAPM. When the operator actuates the switch to adjust the pedals, the MSMAPM controls the adjustable pedals motor movement with input from the adjustable pedals sensor. This sensor allows pedal adjustment and memory functions to be recalled from the driver door mounted memory buttons or the RKE transmitters. The adjustable pedals will not operate when in an active cruise control state or when the vehicle is in reverse. Part 1 of 2 AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM AND OCCUPANT CLASSIFICATION SYSTEM The Airbag System contains the following components: Occupant Restraint Controller (ORC), Air-bag Warning Indicator, Clockspring, Driver and Passenger dual squib Airbags, Driver and Passenger Seat belt Tensioner (SBT), Driver and Passenger Hall-effect Seat Belt Buckle Switches (SBS), Left and Right Side Curtain Airbags, and Front and Side Impact Sensors. The ORC also monitors the Occupant Classification System (OCS) for the presence of a passenger in the front outer seat. The Occupant Classification System contains the following components: Occupant Classification Module (OCM), Bladder and Sensor, Belt Tension Sensor, and Passenger Airbag off Indicator. The Occupant Restraint Controller (ORC) supports staged airbag deployment and remote impact sensing. Staged deployment is the ability to trigger airbag system squib inflators individually as needed to provide the appropriate restraint for the severity of the impact. The ORC has four major functions: PCI Bus communications, onboard diagnostics, impact sensing, and component deployment. The ORC also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the front airbag components for two seconds following a battery disconnect or failure during an impact. The ORC is secured to the floor panel transmission tunnel below the instrument panel inside the vehicle. The ORC cannot be repaired or adjusted. The ORC sends and/or receives PCI Bus messages with the Instrument Cluster (MIC), Body Control Module (BCM), and Powertrain Control Module (PCM). Diagnostic trouble codes will be set if the communication with these modules is lost or contains invalid information. The microprocessor in the ORC monitors the front impact sensor signals and the airbag system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sends a message to the instrument cluster via PCI bus to turn on the Airbag Warning Indicator. The ORC can set both active and stored diagnostic trouble codes to aid in diagnosing system problems. See DIAGNOSTIC TROUBLE CODES. The ORC uses an internal accelerometer, two front sensors and six side impact sensors, to sense the rate of vehicle deceleration and provide verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ORC microprocessor determines when the deceleration rate is severe enough to require airbag system protection. The ORC also uses the driver and passenger seat belt switch status (buckled or unbuckled) to determine the level of driver airbag deployment, low medium or high. When the programmed conditions are met, the ORC sends an electrical signal to deploy the appropriate airbag system components. WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS CAN RESULT IS ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. - NEVER STRIKE OR KICK THE OCCUPANT RESTRAINT CONTROLLER, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. The Airbag Warning Indicator is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4039 turned to the run or start position, the ORC performs a lamp check by turning the Airbag Warning Indicator on for 6-8 seconds. After the lamp check, if the indicator turns off, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes off, there is usually an intermittent problem in the system. DRIVER AIRBAG The airbag protective trim cover is the most visible part of the driver side airbag system. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. When supplied with the proper electrical signal, the inflator or inflators discharge the gas directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE DRIVER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 17236.89 kPa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. CAUTION: Deployed Front Air Bags may or may not have live pyrotechnic material within the air bag inflator. Do not dispose of Driver and Passenger Airbags unless you are sure of complete deployment. Please refer to the Hazardous Substance Control System for Proper Disposal. Dispose of deployed air bags in a manner consistent with state, provincial, local, and federal regulations. Use the following table to identify the status of the Airbag Squib. AIRBAG SQUIB STATUS 1. Using a DRBIII(R) read Airbag DTC's If the following active codes are present: If neither of the following codes is an active code: ACTIVE DTC SQUIB STATUS Driver squib 1 open Driver Squib 2 open Status of Airbag is Unknown. CLOCKSPRING The clockspring is mounted on the steering column under the steering wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wiring and the driver airbag, the horn, and the vehicle speed control switches if equipped. The clockspring Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4040 must be properly centered when it is reinstalled on the steering column following any service procedure, or it could be damaged. The clockspring cannot be repaired and it must be replaced. PASSENGER AIRBAG The front passenger airbag is equipped with dual stage squib inflators. When supplied with the proper electrical signal the inflator or inflators discharge the gas directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS INERT GAS PRESSURIZED TO 17236.89 kPa (2500 PSI). DO NOT ATTEMPT TO IS MANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR.DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. AIRBAG SQUIB STATUS 1. Using a DRBIII(R) read Airbag DTC's If the following active codes are present: If neither of the following codes is an active code: ACTIVE DTC SQUIB STATUS Passenger squib 1 open Passenger squib 2 open Status of Airbag is Unknown. CAUTION: Deployed Front Air Bags may or may not have live pyrotechnic material within the air bag inflator. Do not dispose of Driver and Passenger Airbags unless you are sure of complete deployment. Please refer to the Hazardous Substance Control System for Proper Disposal. Dispose of deployed air bags in a manner consistent with state, provincial, local, and federal regulations. Use the following table to identify the status of the Airbag Squib. SEAT BELT TENSIONER (SBT) The driver and passenger seat belt (buckle) tensioners are mounted to the inboard side of the front seats. The seat belt buckle and seat belt switch are connected directly to the seat belt tensioner cable. At the onset of an impact event the ORC uses the seat belt tensioner to rapidly retract the seat belt buckles. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. The seat belt tensioner cannot be repaired, if damaged or defective it must be replaced. The ORC continuously monitors the resistance of the seat belt tensioner circuits for open and shorted conditions. SEAT BELT SWITCHES (SBS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4041 The hall-effect driver and passenger seat belt switches provide the seat belt status, buckled or unbuckled, via hardwired inputs to the ORC. If the seat belt switch is damaged or defective the seat belt tensioner must be replaced. The ORC continuously monitors the seat belt switch circuits for open and shorted conditions. DRIVER KNEE BLOCKER AIRBAG The most visible part of the Driver Knee Blocker Airbag is the knee blocker trim cover. The knee blocker trim cover and airbag are mounted directly to the instrument panel structure below the steering column. When supplied with the proper electrical signal, the inflator discharges the gas directly into the airbag. The airbag cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: - DO NOT ATTEMPT TO MODIFY ANY PART OF YOUR ADVANCED AIRBAG SYSTEM. THE AIRBAG MAY INFLATE ACCIDENTALLY OR MAY NOT FUNCTION PROPERLY IF MODIFICATIONS ARE MADE. TAKE YOUR VEHICLE TO AN AUTHORIZED DEALER FOR ANY ADVANCED AIRBAG SYSTEM SERVICE. IF YOU'RE SEAT INCLUDING YOUR TRIM COVER AND CUSHION NEEDS TO BE SERVICED IN ANY WAY (INCLUDING REMOVAL OR LOOSENING/TIGHTENING OF EAT ATTACHMENT BOLTS), TAKE THE VEHICLE TO YOUR AUTHORIZED DEALER. ONLY MANUFACTURER APPROVED SEAT ACCESSORIES MAY BE USED. CONTACT YOUR AUTHORIZED DEALER IF IT IS NECESSARY TO MODIFY AN ADVANCED AIRBAG SYSTEM FOR PERSONS WITH DISABILITIES. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. FRONT AND SIDE IMPACT SENSOR The front and side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, and combined with the ORC Accelerometer Sensor provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller. The ORC microprocessor continuously monitors all of the front and side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a system fault, it sets a Diagnostic Trouble Code and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor signal and ground circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor signal circuit. If the sensor is dropped it must be replaced. CAUTION: Do not remove or install the impact sensors while the sensor is connected to the vehicle wiring. OCCUPANT CLASSIFICATION SYSTEM A non-calibrated Occupant Classification Module (OCM) is the only component of the Occupant Classification System (OCS) that is available for separate service replacement, as outlined in the procedures that follow. The OCS components of the passenger side front seat cushion including the cushion frame, springs, pad, seat weight bladder and pressure sensor, seat cushion foam and the OCM are a factory-calibrated and assembled unit. Once this unit is connected to a vehicle electrically, the calibration settings are uploaded from the OCM and stored in the memory of the Airbag Control Module (ORC). If only the OCM is subsequently replaced, the new, non-calibrated OCM learns the proper calibration settings from the ORC after it is connected to the vehicle electrically. If any of the remaining OCS components of the passenger side, front seat cushion require replacement, they are serviced only as a factory calibrated, assembled, and tamper-evident service replacement package. This package includes the assembled frame, springs, pad, seat weight bladder and pressure sensor, foam, wiring and a calibrated OCM. When installing this package, always replace all of the existing components with the new components as a unit. Do not attempt to separate or disconnect any of the new OCS components contained in the service replacement package from each other, and do not attempt to reuse any of the replaced components in this or any other vehicle. Once any of the original factory-installed components except the OCM have been replaced with the service replacement package components, the OCM can only be serviced by replacing the entire passenger side front seat cushion unit with another complete service replacement package. CAUTION: On vehicles equipped with the Occupant Classification System (OCS), never replace both the Airbag Control Module (ORC) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one. Then perform the supplemental restraint verification test before replacing the other. Both the ORC and the OCM store OCS calibration data, which they transfer to one another when one of them is replaced. If both are replaced at the same time, an irreversible fault will be set in both modules. The OCM is subsystem of the Airbag Control Module (ORC). Therefore the OCM bus message updates the ORC with the front passenger seat information via PCI Bus message. The ORC then controls the Passenger Off indicator and the Airbag Warning Indicator to provide system onboard diagnostic feedback. All OCS wiring repairs are prohibited; when wiring problems are diagnosed a Bladder Repair Kit is the only approved repair. Part 2 of 2 PASSENGER AIRBAG OFF INDICATOR Vehicles equipped with the Occupant Classification System (OCS) include a passenger airbag off indicator located in the Switch Bank in the center of the instrument panel. Vehicles without OCS have a blank lens installed in the instrument panel. At ignition on, for a system test, the ORC low side driver grounds a yellow Light Emitting Diode (LED) circuit causing the PASS AIRBAG OFF Indicator text and icon to be illuminated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4042 SEAT WEIGHT SENSOR Vehicles equipped with the Occupant Classification System (OCS) have a seat weight bladder and pressure sensor unit that is integral to the passenger front seat cushion. The pressure sensor receives a nominal five volts and a ground through dedicated hardwired circuits from the OCM. The OCM then monitors the pressure sensor output voltage. SEAT BELT TENSION SENSOR - BTS The Belt Tension Sensor (BTS) is designed to measure belt tension as an input to a passenger Occupant Classification System (OCS). It is used to detect high cinch loads associated with child seats and compensate for the seat cushion load to correctly classify occupant size. When a load is applied to the seat belt, the belt tension sensor measures the load. As the load changes, the circuitry of the belt tension sensor changes the output voltage of the sensor. The belt tension sensor receives a nominal five volts and a ground through dedicated hardwired circuits from the OCM. The OCM then monitors the belt tension sensor output voltage on a dedicated hardwired data communication circuit. If the vehicle has experienced any impact(s) resulting in deployment of a pyrotechnic device of any kind (airbag, seatbelt tensioner, side curtain, etc.) within the vehicle, the entire passenger seat belt retractor assembly, including the BTS, shall be replaced. Additionally, if the seat belt webbing has become cut, frayed, or worn; or if the stitching has become damaged in any way, the entire passenger seat belt retractor assembly, including the BTS, shall be replaced. The belt tension sensor cannot be repaired and, if faulty or damaged, the entire passenger side front seat belt and retractor unit must be replaced. The OCM Verification Test will also provide a BTS Verification procedure to verify the BTS function. This verification procedure requires the Miller Special Tool #8828. BLADDER REPAIR KIT There are only three replaceable components in the OCS, Occupant Classification Module, Bladder Repair Kit and the Passenger Airbag OFF Indicator. The Bladder repair kit contains the OCS bladder, wire harnesses, pressure sensor (Seat Weight Sensor), module, seat cushion and other related structural and sound deadening components. The module and sensor connector must have a Tamper Evident material installed on the service kit module and sensor connectors. This material provides visible evidence that the assembly has been separated after the calibration process was completed. Do not install a Bladder Repair Kit if it appears that any of the components have been disconnected. The OCM can be replaced if the Airbag Control Module has uploaded the seat calibration into memory in a previous ignition cycle and the new OCM has a blank VIN and no calibration data stored in memory. NOTE: - An OCM can only be replaced in a passenger front seat if the seat is equipped with the original OCS module, bladder, sensor and wiring. - Servicing the OCS may create additional active and stored trouble codes that must be resolved before the vehicle can be returned to the owner. The OCS Verification Test will also set active DTC's if the procedure is not completed successfully. The Miller Special Tool, MRL-9077 and the DRBIII are needed to successfully complete the system Verification Test. The DRBIII(R) may report the following NEW DRBIII(R) FEATURE ORC Menu The DRBIII(R) ORC System Test screen will display the following: 2VIN verification - Original VIN and Current VIN 2PCM Monitor - PCM Active On The Bus or PCM Not Active On The Bus The DRBIII(R) ORC Input/Outputs screen will display the following: - OCM Status: - Seat Class 0 (Empty) - Seat Cass 1 (Rear Facing Infant car Seat or RFIS) - Seat Class 2 (6 year old or Child) - Seat Class 3 (greater than or equal to 5th Percentile Female) - Seat Class 4 (less than 5th Percentile Female) - Seat Class 5 (Undetermined) The DRBIII(R) ORC Miscellaneous screen will display the following: - Configure Airbag On-Off Switch 1. No Airbag On-Off Switch 2. Pass OCM Only OCS Menu The DRBIII(R) OCM Input/Output screen will display the following: - OCS Status - 90, 919, 929, 939, 949, 959 The DRBIII(R) OCM Sensors screen will display the following: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4043 - Bladder Output - XXX A/D counts - Pas BTS Output - XXX A/D counts The DRBIII(R) OCM OCS Info Monitor screen will display the following: - Pass BTS -- Enabled or Disabled System Verification The DRBIII(R) OCM System Test screen will display the following: - PCM Monitor - PCM Active On The Bus or PCM Not Active On The Bus - Clear VIN Mismatch - Clear VIN Mismatch Complete - VIN Verification - Original VIN and Current VIN Clear VIN Mismatch - OCS Verification - OCS Verification Test process errors: Test In Progress Mode 33 Not Supported Subfunction not supported Test Busy - Repeat Test Conditions for Test Not Correct Routine Already Running Routine was Never Started Press any key to continue, then restart the verification test. Test failed conditions: Test Failed - Active DTC's Present Test Failed - Seat is Empty Test Failed - Seat Occupied Test Failed - Weight Above Threshold Test Failed - Weight Below Threshold Test Failed - Temperature Out of Range Test Failed - Seat Pressure Too High Test Failed - Seat Pressure Too Low Test Failed - Seat Pressure Not Stable Test Failed - Temperature Out of Range Test Failed - Seat Pressure Too Low Test Failed - Power Up Time Too Short Test Failed - Power Up Time Too Long Test Failed - K Empty Count is 0 Test Failed - No EOL Calibration Test Failed - K Allow is FF Allow the vehicle seat and interior temperature to stabilize, check voltage supplies and repair any other active DTC's before restarting the System Verification test. The OCS has been Verified or The OCS has NOT been Verified WARNING: - TO AVOID PERSONAL INJURY OR DEATH, TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING. - TO AVOID PERSONAL INJURY OR DEATH, TURN THE IGNITION ON, THEN RECONNECT THE BATTERY. - TO AVOID PERSONAL INJURY OR DEATH ON VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS), ONLY THE OCCUPANT CLASSIFICATION MODULE (OCM) AND THE PASSENGER SEAT BLADDER AND CUSHION SERVICE KIT ARE THE ONLY PARTS SERVICED. - IF THE OCCUPANT CLASSIFICATION MODULE IS DROPPED AT ANY TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. TO AVOID PERSONAL INJURY OR DEATH ON VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS), ONLY THE OCCUPANT CLASSIFICATION MODULE (OCM) AND THE SEAT CUSHION TRIM MAY BE SERVICED SEPARATELY. ALL OTHER COMPONENTS OF THE PASSENGER SIDE FRONT SEAT CUSHION ASSEMBLY MUST BE SERVICED ONLY AS A COMPLETE FACTORY-CALIBRATED, ASSEMBLED AND TAMPER-EVIDENT SERVICE REPLACEMENT PACKAGE. THIS PACKAGE INCLUDES THE FRAME, SPRINGS, PAD, BLADDER AND PRESSURE SENSOR, FOAM, WIRING AND A CALIBRATED OCM. WHEN INSTALLING THIS PACKAGE ALWAYS REPLACE ALL OF THE EXISTING COMPONENTS WITH THE NEW COMPONENTS AS A UNIT. DO NOT ATTEMPT TO SEPARATE OR DISCONNECT Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4044 ANY OF THE NEW OCS COMPONENTS IN THE SERVICE REPLACEMENT PACKAGE FROM EACH OTHER, AND DO NOT ATTEMPT TO REUSE ANY OF THE REPLACED COMPONENTS IN THIS OR ANY OTHER VEHICLE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN FAILURE OF THE PASSENGER AIRBAG TO DEPLOY WHEN REQUIRED, OR IN PASSENGER AIRBAG DEPLOYMENT WHEN NOT REQUIRED. SPECIAL TOOLS Some airbag diagnostic tests will require the use of special tools, airbag load tools, 8443 for testing squib circuits and the Occupant Classification Seat Weight Tool 9077. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of a Driver or Passenger Airbag, curtain airbag, clockspring, or seat belt tensioner (use a jumper if needed). Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective component has been removed from the system and should be replaced. If the DTC is still active, continue this process until all components in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed the squib wiring can be tested for open and shorted conditions. DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes with the DRBIII(R). This will direct you to the specific test(s) that must be performed. In certain test procedures diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The code becomes active as soon as the malfunction is detected or key-on, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the Occupant Restraint Controller checks that circuit or component. It is impossible to erase an active code. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. STORED CODES Airbag codes are automatically stored in the ORC's memory as soon as the malfunction is detected. A stored code indicates there was an active code present at some time. When a trouble code occurs, the Airbag Warning Indicator illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). Once the code is no longer active, the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected will be displayed. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. The ignition cycle counter will be reset and diagnostic trouble code will continue to be a stored code, If the malfunction reoccurs before the count reaches 100. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. Maintain a safe distance from all airbags while performing the following inspection. If no obvious problems are found, erase stored codes, and with the ignition on wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Audio System Some of the radios are on the PCI Bus system. The PCI Bus inputs into the radio are used for VF dimming, remote steering wheel controls and cabin EQ preference. PCI Bus outputs from the radio are used for the Name Brand Speaker (NBS) relay activation, as well as cabin EQ preference. The radios have the capability of containing multiple vehicle unique equalization curves (cabin EQ preferences) within the radio. These curves will reside in the radio's flash memory. The radio is capable of storing up to 20 unique equalization curves. The latent curves can be selected via the Front Control Module transmitting a PCI Bus message to the radio in response to a radio request for equalization message. Upon receipt of a valid equalization select message response, the radio will switch to output the corresponding equalization curve. All the radios are capable of displaying faults and allowing certain actuation tests through the use of the DRBIII(R). When attempting to perform PCI Bus diagnostics, the first step is to identify the radio in use in the vehicle. When trouble shooting output shorts or 'output' error messages, the following applies: On radios without an external amplifier, the term output refers to the path between the radio and the speaker. This type of circuit can be monitored all the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4045 way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio, or wiring could be at fault. On radios with an external amplifier, the term 'output' refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. NAVIGATION RADIO The optional navigation radio system receives GPS signals from up to eight satellites to display the position and direction of the vehicle. Map information is supplied through a DVD-ROM. An electronic gyrosensor and the vehicle's speed sensor enable the system to display the present vehicle position even in locations where GPS signals may be blocked. When a destination is selected, the navigation system uses information from the map to quickly calculate a route. As the vehicle is driven along the chosen route, the operator is guided with pictorial displays and voice prompts. For complete operating instructions, refer to the manual included with the vehicle. REMOTE RADIO CONTROLS These radios can be controlled via remote radio switches (optional). These switches are located on the back side of the steering wheel. They control mode, preset, seek up, seek down, volume up and volume down functions. These functions are inputs to the Body Control Module and can be read with the DRBIII(R) under 'body computer'. The switches are a multiplexed signal to the BCM. The radio control MUX circuit is a 5 volt line that is pulled to ground through different value resistors built into the switches. This causes a voltage drop to be seen by the BCM and it sends a specific message to the radio on the PCI Bus circuit. The radio then responses to the message. This circuit is fairly simple to troubleshoot. The circuit must be complete from the switches in the steering wheel to the BCM. The ground must be complete so that the switches can cause the voltage drop for the BCM to see. The circuit passes through the clockspring so continuity through this devise must be verified. CD CHANGER The new in-dash CD Changer is designed to fit into the existing cubby bin in the center stack. This new cartridge-less CD Changer is controlled by your radio, and allows you to individually load up to four discs at a time. However, due to its compact design, the CD Changer can only carry out one operation at a time. For example, you can not load a new disc while playing another at the same time. Each operation happens sequentially. The radio unit installed with your system provides control over all features of the CD Changer with the exception of the CD load and eject functions, which are controlled by buttons located on the front of the CD Changer. The radio also supplies the power, ground, PCI Bus, left and right speaker output through a single DIN cable. All features you would expect, such as Disc Up/Down, Track Up/ Down, Random and Scan are controlled by the radio, which also displays all relevant CD Changer information on the radio display. The CD Changer contains a Load/Eject button and an indicator light for each of the four disc positions. The individual light indicates whether a CD is currently loaded in that particular chamber of the CD Changer. Pressing the individual Load/Eject button for a particular chamber will eject a disc currently present in that chamber. If the chamber is currently empty, actuating the Load/Eject button will position that chamber to receive and load a new disc in that chamber. DVD/CD CHANGER The DVD/CD Changer (if equipped) is located in the instrument panel below the radio. The DVD/CD Changer can hold one DVD at a time. Three RCA jacks on the front of the unit will allow the use of MP3 players, video systems or camcorders. Body Control Module The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (PCI). This network consists of the powertrain control module (PCM), the engine control module (ECM) diesel, the mechanical instrument cluster (MIC), the front control module (FCM), the occupant restraint controller (ORC), the occupant classification module (OCM), the overhead console, the ABS module, the hands free module (HFM), the park assist module, the HVAC control module (ATC & MTC), the power sliding door (Left & Right) modules (PSD), the power liftgate module (PLG), the Audio system (which includes the Radio, DVD, CD Changer and Amplifier), the memory seat/mirror/ adjustable pedals module (MSMAPM), the RKE/ Thatcham alarm module (export), the transmission control module (Diesel only) and the sentry key remote entry module (SKREEM). The BCM is operational when battery power is supplied to the module. The body control module provides the following features: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4046 - Power Door Locks - Automatic Door Lock - Door Lock Inhibit - Central Locking (with VTSS Only) - Battery Protection - The BCM will automatically turn off all exterior lamps after 3 minutes and all interior lamps after 15 minutes after the ignition is turned off, if they are not turned off by the driver. - Chime Driver - Compass/Minitrip Support - Interior Lighting (Courtesy/Reading Lamps) - BCM Diagnostic Reporting - Electronic Liftgate Release (with Power Door Locks) - Exterior Lighting - Headlamp Time Delay (with/without Auto headlamps) - Automatic Headlamps (with electrochromatic mirror) - Illuminated Entry - Fade to Off This feature dims the interior lighting (courtesy lamps) gradually if the BCM does not receive any new inputs that would cause the interior lamps to remain on. - PWM Instrument Panel Dimming - Door Lock Inhibit This feature disables the door lock functions if the key is in the ignition and either front door is ajar. Pressing the RKE lock/unlock button under these conditions, result in normal lock/unlock activation. - Power Sliding Door Switch Inputs The BCM has 4 switch inputs for the power sliding door feature: Located in the overhead console are the Left and Right side sliding door switches to activate either or both sliding doors under the proper conditions. Also there are B-Pillar switches located on the Left and Right B-pillar posts. - Power Liftgate Switch Input The BCM has 1 Liftgate switch input located in the overhead console - Power Lockout Switch Input The BCM has 1 Lockout switch that when enabled will disable the B-Pillar sliding door switches from activating either sliding door when depressed. When replacing a body control module there are 2 modules available, a Base and a Midline. The Midline controller is used on vehicles that have Power Door Locks. If a vehicle is equipped with the Vehicle Theft Security System, the midline controller becomes a premium when the theft feature is enabled. NOTE: Do not swap the body control module between vehicles or body control modules off the shelf. Engineering does not recommend that service, dealers or the plant swap Body Control Modules (BCM) between vehicles or off the shelf. The BCM has internal diagnostic capability that assists in diagnosing the system. When an 'open' or a 'Short' circuit exists, the diagnostic tool can be used to read the BCM codes. The codes are very descriptive in identifying the appropriate feature that has faulted. The BCM also learns what features are on the vehicle and if modules are swapped the BCM could set false DTC's based on what it learned. Chime Warning System The BCM monitors the door/liftgate ajar switches, multifunction switches, headlight switch, ignition switch, PCI bus, and the diagnostic tool to perform various chime operations. The BCM uses a low-side driver to control the chime located in the cluster. The chime system provides the Driver with warning chimes for: - Seat belt - Exterior lights on - Key-in Ignition - Key-in Accessory - Engine temperature critical - Low washer fluid - Turn signals on - Dome light on - Low oil pressure - Any warning lamp announcement - High-speed warning Gulf Coast Countries (GCC) only The output sound intensity of the chime is approximately 72 decibels. CHIME PRIORITY Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4047 The following list indicates the priority of the chime when more than one chime is active at the same time: - Seat belt warning - High-speed warning Gulf Coast Countries (GCC) only - Turn signal on - Chime request - Warning lamp announcement The cluster is responsible to set priority on all warning lamp announcement chimes. CHIME ON CONDITIONS The following is a list of the chime warnings and when they will sound. Driver's Seatbelt Unbuckled: Sounds for approximately 6 ± 2 seconds when the ignition is turned on driver's seat belt is not buckled, as a reminder to the driver to buckle the seat belt. Exterior Lights On:Ignition is in the lock position, the driver door is ajar, and the headlight switch is left in any position, other than auto or off.The chime will sound as a warning to the driver until one of the above conditions is removed or until the battery protection time of 3 minutes has expired. Key-In Ignition: Ignition is in the lock position, driver door is ajar and the key is in the ignition. The chime will sound until one of the above conditions is removed or until the battery protection time of 15 minutes has expired. Turn Signal On: When the BCM detects a turn signal input continuously for 1.0 mile/0.6 km and the vehicle speed is greater than 15 mph/24 kph, the chime will sound until the specific turn signal is cancelled. Dome Lights On: Ignition is in the lock position, driver door ajar, and the dome light switch is left in the on position. The chime will sound until one of the above conditions is removed or until the battery protection time of 15 minutes has expired. Low Oil Pressure: The chime will sound when the engine is operating and the oil pressure drops below 4 psi/27.5 kPa. Engine Temperature Critical: The chime will sound when the engine is operating and the coolant temperature exceeds 252° F/122° C or 234° C/112° C(diesel). The chime is continuous at 257° F/ 125° C and will chime for 4 minutes and stop if the temperature drops below 255° F/123° C. Low Washer The chime will sound when the Fluid washer fluid drops below a specific level. Warning Lamp Announcement: A chime will sound to alert the driver to scan the instrument panel and overhead console to see which warning lamp is illuminated. The door/liftgate ajar warning lamp will appear without a chime if the vehicle is running and a door or the liftgate is opened. A chime will sound if the door or liftgate is still open and the vehicle speed is greater than 4 mph/6 kph. High-speed warning Gulf Coast Countries (GCC) only The chime will sound, acting as a warning to the driver that the vehicle speed has exceed 75 mph ± 2/120 kph ± 3. WARNING LAMP ANNOUNCEMENT Low Fuel Lamp: The cluster will request a single chime after the indicator is illuminated. Volt Lamp: The cluster will request a single chime after the indicator is illuminated. Oil Pressure Lamp: The cluster will request a single chime after illuminating the indicator above 450 rpm vehicle operation. Liftgate Ajar Lamp: The BCM determines when to chime for liftgate ajar. Fasten Seat Belt Lamp: The MIC will request a single chime from the BCM when the ignition is turned to the unlock/ run/start positions if the driver seat belt is not buckled and 2 seconds after seatbelt warning chime ends. Check Engine Lamp: The cluster will request a single chime after the indicator is illuminated. Low Washer Fluid Lamp: The cluster will request a single chime after the indicator is illuminated. Engine Temperature Lamp: The cluster will request a single chime when the indicator is first illuminated at 252° F/122° C. OTHER CHIME ON CONDITIONS Programming of an Additional Key Fob: A single cluster chime will sound, which signals that the program mode has been initiated. Programming for Rolling Door Locks: When the programming has been completed, a single tone from the chime system, will occur. Communication Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4048 The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25 and is white with a violet tracer. Additional tracer colors may be added to the violet in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on the RS/RG: - Body Control Module - Front Control Module - Occupant Restraint Controller - Occupant Classification Module - Controller Antilock Brake (MK20E) - Antilock Brake Module (MK25E) - Powertrain Control Module (Gas) - Transmission Control Module (Diesel Auto Only) - Engine Control Module (Diesel) - Radio - Amplifier - CD Changer - DVD/CD Changer - Hands Free Module - Automatic Temperature Control Module - A/C Heater Control Module (MTC) - Sentry Key Remote Entry Module (SKREEM) - Memory Seat/Mirror/Adjustable Pedals Module (MSMAPM) - Overhead Console - Mechanical Instrument Cluster - Left Sliding Door Control Module - Right Sliding Door Control Module - Thatcham Alarm Module (Export) - Power Liftgate Module - Park Assist Module Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRBIII(R) lab scope. The 12 v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open PCI circuit at the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: - All gauges on the MIC stay at zero - All telltales on MIC illuminate - MIC backlighting at full intensity - Dashed lines in the overhead console ambient temperature display - No response received from any module on the PCI bus (except the PCM/ECM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRBIII(R). Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected,suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRBIII(R) If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRBIII(R) may display BUS ± SIGNAL OPEN or NO RESPONSE to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRBIII(R) and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. NOTE: For 2005 model year, some vehicles will integrate the Transmission Control Module and Powertrain Control Module into a single control module. This new module is the Next Generation Controller for DaimlerChrysler and will be referred to as the Powertrain Control Module (PCM). The Transmission Control Module is part of the Powertrain Control Module. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4049 Diagnostic procedures and DTC numbers are some of the changes you will see which reflect the new combined module technology. The PCM will have four color coded connectors C1 through C4, (C1-BLK, C2-ORANGE, C3-WHITE, C4-GREEN), each PCM connector will have 38 pins each. Two new tools are used for probing and repairing the New PCM connectors. A New tool to release the pins from the PCM connectors Miller #3638 is introduced, you must use the Miller tool #3638 to release the connector pins or harness and connector damage will occur. Also a New tool for probing connectors Miller #8815 is introduced, you must use the Miller tool #8815 to probe the PCM pins or harness and connector damage will occur. There is also a new Verification test and module replacement procedure for the PCM. Door Ajar System The door ajar and liftgate ajar states are used as inputs for the Body Control Module (BCM). The BCM uses these inputs to determine exactly what position the doors and liftgate are in. The DRBIII(R) will display the state of the door ajar and the liftgate ajar switches in Inputs/Outputs. It's important to note, that when any door, or the liftgate is closed, the switch state on the DRBIII(R) will show OPEN. When any door, or the liftgate is open the switch state on the DRBIII(R) will show CLOSED. During diagnosis, if a door or the liftgate is closed and the DRBIII(R) displays the switch state as CLOSED, it indicates a shorted ajar circuit. If the door or the liftgate is open and the DRBIII(R) displays the switch state as OPEN, it indicates an open ajar circuit. Exterior Lighting System HEADLAMP POWER The Headlamp Switch is a direct input to the BCM. The BCM sends a BUS message to the FCM informing it of a headlamp switch status change. The FCM then turns on power to the headlamps through four fuseless circuits. These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied to each filament in a separate circuit. For vehicles equipped with daytime running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination. HEADLAMP SWITCH The Headlamp Switch uses a multiplexed (MUX) circuit to the Body Control Module (BCM). The Headlamp Switch controls the Fog lamp relay, Park lamps and the Low and High headlamps. The BCM then sends a signal through the PCI Bus line to the FCM as to what state the switch has selected. The FCM energizes the high side output drivers to turn ON the desired lamps. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4050 PARK LAMP RELAY The Park Lamp Switch is a direct input to the BCM. The BCM sends a BUS message to the FCM informing it to turn on the park lamp relay. The park lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. FOG LAMP RELAY The Fog Lamp switch is a direct input to the BCM. The BCM sends a BUS message to the FCM informing it to turn on the fog lamp relay. The fog lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Fog lamp functionality is not equipped on all vehicles. The FCM learns that the vehicle is equipped with fog lamps by reading the BCM BUS message. FOG LAMPS The BCM controls the operation of the fog lamp relay that turns the fog lamps ON and OFF. The Fog lamps can only be ON when the park and low beams are ON. If the high beams are switched ON then the Fog lamps will be automatically turned OFF. EXTERIOR LIGHTING BATTERY SAVER The BCM monitors the status of, and controls, the Park Lamps, Headlamps and Fog Lamp relays. If any exterior lamps are left ON after the ignition is turned OFF, the BCM will turn them OFF after 3 minutes. AUTO HEADLAMPS This feature is available on vehicles equipped with both the Electrocromatic Mirror (ECM) and the Compass/Mini-Trip Computer (CMTC). When the BCM detects a day/night signal from the CMTC, an ECM is present and Auto Headlamp mode is selected. Front Control Module The Front Control Module (FCM) is an electrical control and interface center located in the engine compartment. When it is mated to the Power Distribution Center (PDC), it is referred to as the Integrated Power Module (IPM). The IPM, with its fuses and relays provides power and signal distribution throughout most of the vehicle. The FCM receives both hard wire and digital electronic inputs from the vehicle electrical system through the PDC. Based on these inputs and the ignition switch position, it provides direct power feeds and relay control to some of the vehicles most critical electrical systems. The Front Control Module provides the following features: Controlled power feeds: - Front airbag system - Headlamp power - EATX module power (4 speed only) - Front washer motor - Rear washer motor - Cabin Heater - Brake shift interlock system Relay controls: - Fog lamp relay (when equipped) - Park lamp relay - Front wiper on relay - Front wiper high/low relay - Accessory relay - Horn relay - Front & rear blower relay - Name brand speakers (NBS) relay - Adjustable pedals relay (non-memory) - Electronic back light (EBL) run only relay Electrical inputs: - Headlamp battery supplies 1 & 2 - Module battery supply - Power ground - Ignition switch RUN or START position status - Ignition switch START only status - PCI Bus - Stop lamp switch - Horn switch - Back-up switch - Wiper park switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4051 - Washer fluid level switch - Brake fluid level switch - Ambient temperature sensor - Right park lamp outage - Left park lamp outage - Battery IOD - Battery (+) connection detection - Flash reprogramming voltage CONTROLLED POWER FEEDS Front airbag system The FCM provides power to the Occupant Restraint Control (ORC) system through two fuseless circuits (ORC RUN/START, and ORC RUN only). These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied while the ignition switch is in the RUN and START positions on pin 48 of the FCM connector, and in the RUN only position on pin 29. Headlamp power The headlamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a headlamp switch status change. The FCM then turns on power to the headlamps through four fuseless circuits. These circuits are electronically controlled and continuously monitored for malfunctions.Power is supplied to each filament in a separate circuit. For vehicles equipped with Daytime Running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination. EATX power The electronic automatic 4 speed transmission module is powered when the ignition switch is in the UNLOCK, RUN or START positions. This circuit is electronically controlled and continuously monitored for malfunctions. Power is supplied through pin 27 of the FCM connector. Front washer motor The front washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The front washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition, the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Rear washer motor The rear washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The rear washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition,the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Cabin Heater When the ignition is in Run, the FCM monitors the PCI bus for the Cabin Heater Activation request. The Automatic or Manual Temperature Control initiates this request only when all conditions for the Cabin Heater activation are favorable. The request carries the status bit that the FCM requires to activate its Cabin Heater Assist Control output. This output is a low side driver (coming from FCM pin 15) which supplies a ground signal to the Cabin Heater (pin 5). When the Cabin Heater receives this ground signal input, it interprets this as an activation signal. The FCM low side driver is also capable of diagnostic sensing. The driver will sense an open circuit when the driver is off, and will sense a short to voltage when the driver is on. The FCM will set DTC's for both of these types of faults. For additional information, refer to Cabin Heater under General Information and Diagnostic Procedures in the manual. Brake shift interlock system The brake shift interlock solenoid receives power from both high side and low side controls inside the FCM. The high side control is on the same circuit as the EATX module power, and the low side control comes through pin 47 of the FCM connector. The solenoid is controlled by the low side driver when the brake pedal is pressed. Both circuits are continuously monitored for malfunctions. RELAY CONTROLS Fog lamp relay The fog lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the fog lamp relay. The fog lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Fog lamp functionality is not equipped on all vehicles. The FCM learns that the vehicle is equipped with fog lamps by reading the BCM PCI Bus message. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4052 Park lamp relay The park lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the park lamp relay. The park lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper on relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper on relay. The front wiper on relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper high/low relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper high/ low relay. The relay switches power between the low speed and high speed windings of the wiper motor. The front wiper high/low relay is powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Accessory relay The accessory relay works in conjunction with the FCM's power accessory delay feature to control the operation of the radio, power windows, washer motors,wiper motors and power outlet. The accessory relay is turned on through low side control on pin 35 of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Depending on the ignition switch position, the accessory relay will remain on or will time-out and turn off. The accessory relay remains on in the RUN and ACCY positions of the ignition switch. In the UNLK and OFF positions, the relay will remain energized for 45 seconds then turn off. During this time-out period, if the driver or passenger doors are opened, the relay will turn off immediately. While the ignition switch is in the START position, the relay will also drop-out, then resume operation. Accessory relay operation is most noticeable by observing the operation of the radio or blower functions. Horn relay The horn relay operates through a direct wire input to the FCM from the horn switch (FCM pin 17) , or a PCI Bus message from the BCM. The relay responds to the horn switch, remote door lock and VTA alarm functions. The horn relay is powered through low side control on pin 10 of the FCM. Under normal operating conditions, if the horn is pressed for longer than 30 seconds, the FCM will automatically deactivate the horn to prevent damage to it. The FCM will re-activate control of the relay after a 25 second cool-down period. This circuit is electronically controlled and continuously monitored for malfunctions. Front and rear blower relay RS with MTC Upon ignition on, the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus.The front blower relay and the rear blower relay, if equipped, are then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. RG with MTC Upon power up (Power switch on), the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus. The front blower relay is then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. Name Brand Speakers (NBS) relay The NBS relay operates through the vehicle bus interface between the radio and the FCM. When the radio is turned on, the radio sends a PCI Bus message to the FCM. The NBS relay is then powered on through low side control on pin 11 of the FCM. The relay supplies power to the amplified speaker, and ground is supplied through the radio. This circuit is electronically controlled and continuously monitored for malfunctions. Electronic Back Light (EBL) relay The rear defrost switch is part of the Automatic Temperature Control or A/C-Heater Control Module (Manual Temp). When the ignition switch is in the RUN position and the rear defrost switch is turned on, the ATC or A/C-Heater Control Module sends a PCI Bus message to the FCM. The EBL run only relay is then powered through low side control on pin 31 of the FCM. The relay provides the high side to the rear window defrost grid, and ground is attached to the vehicle body. The FCM will only allow the rear defrost to operate in the RUN position. This circuit is electronically controlled and continuously monitored for malfunctions. Adjustable Pedals Relay (Non-Memory) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4053 The Adjustable Pedals Relay is only on nonmemory Adjustable Pedals System equipped vehicles. The relay is supplied battery voltage from the IPM and is electronically controlled with a low side driver within the FCM. The relay is energized when the transmission is in reverse and when cruise control operation is engaged. This action disables the Adjustable Pedals System from movement. This circuit is continuously monitored for proper function. ELECTRICAL INPUTS Headlamp battery supplies 1 & 2 - 12 volt input on pins 1 and 2. Battery supply voltage for switching headlamp circuits only. Module battery supply - 12 volt input on pin 9. Battery supply voltage for all other FCM operations. Power ground - Ground source on pin 8 for all FCM operations. Ignition switch RUN or START position status - 12 volt input on pin 37. Allows the FCM to determine the ignition switch status for related FCM operations. PCI Bus - Approximately 7.5 volt input on pin 22. Allows the FCM to communicate with other modules on the vehicle bus. Stop lamp Switch status - 12 volt input on pin 44. Provides for brake shift interlock function. Horn Switch - Ground input on pin 17. Primary means for engaging the horn. Back-up switch - Ground input on pin 39. Input is converted to a PCI Bus status message for use by other modules. Wiper park switch - Ground input on pin 16. Used to determine park placement of wipers. Also used as feedback to FCM to determine correct operating mode of wipers. Washer fluid level switch - Ground input to pull-up on pin 18. Ground is switched into the circuit when washer bottle fluid level is low. Brake fluid level switch - Ground input to pull-up on pin 36. Ground is switched into the circuit when brake fluid level is low. Ambient temperature sensor - Resistive input to pull-up on pin 25. Corresponding voltage level is converted to a PCI Bus message for use by other modules on the bus. Right park lamp outage - 12 volt input on pin 21. Used to determine if right park lamp circuit is operating properly. Left park lamp outage - 12 volt input on pin 41. Used to determine if left park lamp circuit is operating properly. Battery IOD - 12 volt input on pin 20. The FCM enters a low power consumption mode when the ignition is turned OFF. This low current draw battery supply keeps the microprocessor functioning in the low power mode. Battery (+) connection detection - 12 volt input on pin 38. The battery connection on the PDC incorporates the use of an internal switch to determine if the connector is properly mated and the Connector Positive Assurance (CPA) is engaged. If the CPA is not properly engaged, a voltage on pin 38 will be interpreted as an unseated connector and a fault will set. Flash programming voltage - 20 volt input on pin 42. When a DRBIII(R) is connected and the proper flash reprogramming sequence is selected, the 20 volt signal will be applied through pin 42. Heating and A/C System AUTOMATIC TEMPERATURE CONTROL (ATC) MODULE USAGE CAUTION: Do not swap ATC Modules from vehicle to vehicle. Software versions differ between models and between model years. Installing a ATC Module with software that is incompatible for a given vehicle can result in either improper or failed HVAC system operation. SYSTEM AVAILABILITY - The ATC system is a Three-Zone Air Conditioning System. SYSTEM CONTROLS The ATC Module: - is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - provides an A/C request over the PCI Bus to the Powertrain Control Module (PCM) when compressor operation is desired. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4054 - for exports with diesel engines, provides a Cabin Heater activation request over the PCI Bus to the Front Control Module (FCM) when conditions are favorable for Cabin Heater operation. - uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - uses input from infrared (I/R) sensors, which measure surface temperature, to maintain occupant comfort levels. The I/R sensors are mounted in the instrument panel center bezel. - can be operated in a manual mode. - provides a blower relay on request over the PCI Bus to the Front Control Module (FCM) when blower operation is desired. - controls front blower operating speed, providing 10 speeds in manual mode and infinite speeds in automatic mode. - provides a cold engine blower lockout function. A Blower Speed Clamping feature minimizes occupant discomfort by controlling the amount of warm air coming out of the HVAC system should the Powertrain Control Module (PCM) disable A/C Compressor operation while the Automatic Temperature Control (ATC) is set in an automatic mode. The PCM disables the A/C compressor if the A/C pressure is too low, if the A/C pressure is too high, if engine overheating is immanent, or if an engine overheating condition exists. The ATC clamps the blower speed if the outside air temperature is greater than 50° F (10° C) and the PCM has disabled the A/C compressor. This means that the ATC will not adjust blower speed automatically when the clamping feature is enabled, e.g. if the clamping feature is enabled while in Auto Lo the blower will continue to run in low speed; if the clamping feature is enabled while in Auto Lo and the operator selects Auto Hi the blower will continue to run in low speed; if the clamping feature is enabled while in Auto Hi the blower will continue to run at the highest speed. In any case the operator can manually change the blower speed as desired. When diagnosing blower related symptoms verify that none of the above conditions for disabling the A/C compressor exist before diagnosing the blower circuits and components. - controls rear blower operating speed, providing 10 speeds in manual mode and infinite speeds in automatic mode. The separate front and rear Blower Motor Controllers operate as follows: When blower operation is desired, the Blower Motor Controller provides a 10.0 volt signal to the ATC Module over a control circuit. The ATC Module provides a variable duty cycle ground to the 10.0 volt signal based on input from the blower switch. When the blower switch is set to LO speed, the ATC Module provides a short duty cycle (less time grounding the signal voltage). As higher blower speeds are requested, the ATC Module increases the duty cycle (more time grounding the signal voltage). When the blower switch reaches HI speed, the duty cycle increases to where the signal pattern is almost a flat line (with brief voltage spikes). - controls the front and rear electric door actuators operation. A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The ATC Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the ATC Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. - activates and deactivates the Rear ATC Switch. The Rear ATC Switch (Three-Zone Only): - provides desired rear blower speed input to the ATC Module. - provides desired rear blend and mode door position input to the ATC Module. The Dual-Zone ATC system uses: - two front, two-wire electric blend door actuators. - one front, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. The Three-Zone ATC system uses: - two front, two-wire electric blend door actuators. - one front, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. - one rear, two-wire electric blend door actuator. - one rear, two-wire electric mode door actuator. System Relays: - The Integrated Power Module (IPM) houses and provides power to the A/C Clutch Relay, Front Blower Motor Relay, and Rear Blower Motor Relay. SYSTEM REVISIONS The 2005 ATC system remains mostly carryover from 2004. Revisions to the 2005 ATC system include: - all new version 0012 software. SYSTEM DIAGNOSTICS Fault detection is through active and stored Diagnostic Trouble Codes (DTC's) - DTC's are displayed the DRBIII(R). - Active DTC's are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTC's are those which occurred in the system since the ATC Module received the last "clear diagnostic info" message. The AC Cooldown Test: - is actuated with the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4055 - checks A/C system performance based on evaporator temperature sensor input. WARNING: DO NOT OPERATE THE DCHA IN AN ENCLOSED AREA SUCH AS A GARAGE THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS VENT THE DCHA's EXHAUST WHEN OPERATING THE DCHA. REFER TO VENTING THE DCHA's EXHAUST UNDER CABIN HEATER IN THE GENERAL INFORMATION PORTION OF THIS SECTION FOR PROPER EXHAUST VENTING INSTRUCTIONS. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. CAUTION: Do not activate the A/C Cooldown Test with the engine off. Failure to follow these instructions can result in internal damage to the DCHA Heater Module. - The FCM monitors the PCI bus for the Cabin Heater Activation request. The request carries the status bit that the FCM requires to activate it's Cabin Heater Assist Control output. This output is a low side driver (coming from FCM pin 15) which supplies a ground signal to the Cabin Heater (pin 5). When the Cabin Heater receives this ground signal input, it interprets this as an activation signal. - The FCM low side driver is also capable of diagnostic sensing. The driver will sense an open circuit when the driver is off, and will sense a short to voltage when the driver is on. The FCM will set DTC's for both of these types of faults. For additional information, refer to Cabin Heater under General Information and Diagnostic Procedures. - will not run the air conditioning portion of this test if ambient temperature is below 12° C (53° F). The forced Cabin Heater activation will occur even if the air conditioning portion of this test fails to initiate because AC Cooldown test criteria was not met. When activated, the DCHA will operate for approximately seven minutes. Three minutes to run and four minutes to purge. - will pass the air conditioning portion of this test if the evaporator temperature drops 6.7° C (20° F) within two minutes of starting this test. - messages (air conditioning related only) display on the DRBIII(R) after running this test. These messages will clear after paging back out of this test. Therefore, it is important to note all of the AC Cooldown test messages before doing so. - All Cabin Heater-related DTC's display under Cabin Heater, Read DTC's. - will cause the DELAY and Snowflake VF segments on the ATC to flash for 162 seconds (RG with DCHA only). If the air conditioning portion of this test fails, the DELAY and Snowflake VF segments will continue to flash until the vehicle is driven more than three miles. MANUAL TEMPERATURE CONTROL (MTC) Vehicle Compatibility For MTC Modules MODULE USAGE SYSTEM AVAILABILITY - Three different types of systems are currently available for these vehicles. Single-Zone Air Conditioning System - Dual-Zone Air Conditioning System - Three-Zone Air Conditioning System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4056 SYSTEM CONTROLS The A/C-Heater Control Module: - is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - provides an A/C request to the Powertrain Control Module (PCM) over the PCI Bus when compressor operation is desired. - uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - for exports with diesel engines, provides a Cabin Heater activation request to the Front Control Module (FCM) over the PCI Bus when conditions are favorable for Cabin Heater operation. - for RS vehicles, provides a blower relay on request to the FCM over the PCI Bus upon ignition on. - for RG vehicles, provides a blower relay on request to the FCM over the PCI Bus when the Power switch on the A/C-Heater Control Module is turned on. - controls front blower operating speed. For RS vehicles, the four speed settings are Low, M1, M2, and High. For RG vehicles the five speed settings are Low, M1, M2, M3, and High. - for RS vehicles uses the blower switch to control system on/off and blower speed. - for RS vehicles uses the rear wiper/washer switch to control rear wiper/washer operation. - for RS vehicles, provides a rear wiper on request to the Body Control Module (BCM) when rear wiper operation is desired. - for RS vehicles, provides a rear washer on request to the Body Control Module (BCM) when rear washer operation is desired. - controls EBL operation. - on three-zone systems, activates and deactivates the Rear A/C-Heater Control. - on three-zone systems, controls rear blower operating speed. The three speed settings are Low, Med, and High. - controls the front and the three-zone system rear electric door actuators operation. A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C - Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. On Three-Zone systems, the Rear A/C-Heater Control: - controls rear blower motor operating speed. The three blower speeds are Low, Med, and High. - provides desired rear blend and mode door position input to the A/C-Heater Control Module. The Single-Zone HVAC system uses: - one, two-wire electric blend door actuator. - one, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. The Dual-Zone HVAC system uses: - two, two-wire electric blend door actuators. - one, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. The Three-Zone HVAC system uses: - two front, two-wire electric blend door actuators. - one front, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. - one rear, two-wire electric blend door actuator. - one rear, two-wire electric mode door actuator. System Relays: - The Integrated Power Module (IPM) houses and provides power to the A/C Clutch Relay, Front Blower Motor Relay, and Rear Blower Motor Relay. SYSTEM REVISIONS The 2005 MTC system remains mostly carryover from 2004. Revisions to the 2005 MTC system include: SYSTEM DIAGNOSTICS Fault detection is through active and stored Diagnostic Trouble Codes (DTC's) - DTC's are displayed by the DRBIII(R). - Active DTC's are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTC's are those which occurred in the system since the A/C-Heater Control Module received the last "clear diagnostic info" message. The A/C Cooldown Test: - is actuated with the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4057 - checks A/C system performance based on evaporator temperature sensor input. - will not run if ambient temperature is below 12.7° C (55° F). - will pass if the evaporator temperature drops 6.7° C (20° F) within two minutes of starting the test. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - for RS vehicles will cause the Rear Wipe/Wash and A/C status indicators on the A/C-Heater Control Module to flash alternately while the test is running. - for RG vehicles will cause the PWR and A/C status indicators on the A/C - Heater Control Module to flash alternately while the test is running. The A/C status indicator will flash twice per second to indicate that the A/C Cooldown Test needs to be run. The A/C status indicator will stop flashing twice per second if either the A/C Cooldown Test returns passed, or if any button on the control is pressed, or if the ignition is cycled and the odometer shows greater than eight miles. The HVAC Door Recalibration function: - is actuated with the DRBIII(R) After completing HVAC Door Recalibration, the DRBIII(R) will the store the total span and the status of each door actuator. Selecting HVAC Door Cal Monitor in the System Tests will display this information. - homes and repositions door actuators. - monitors for door span faults on the actuator circuits. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - for RS vehicles will cause the Rear Wipe/Wash and RECIRC status indicators on the A/C-Heater Control Module to flash alternately while the test is running. - for RG vehicles will cause the PWR and RECIRC status indicators on the A/C - Heater Control Module to flash alternately while the test is running. The RECIRC status indicator will flash twice per second to indicate that the HVAC Door Recalibration Test needs to be run. The RECIRC status indicator will stop flashing twice per second if either the HVAC Door Recalibration Test returns passed, or if any button on the control is pressed, or if the ignition is cycled and the odometer shows greater than eight miles. The Actuator Circuit Test: - is actuated with the DRBIII(R). - monitors for shorted actuator circuits. - allows service to easily diagnose and troubleshoot up to three simultaneous shorts. - supplements the continuous diagnostics on the actuator drive system. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. When Performing the Actuator Circuit Test CAUTION: - Shorted rear door driver circuits can cause additional Actuator Circuit Test messages to set for circuits where no condition exists to cause a fault. - To ensure a proper diagnosis, repair all Short Too Complex messages first, all rear door driver circuit related messages second, all common door driver circuit related messages third, and all front door driver circuit related messages last. - The DRBIII(R) can display up to three Actuator Circuit Test messages at a time. After repairing each Actuator Circuit Test message, cycle the ignition switch, then rerun the Actuator Circuit Test to ensure no new messages exist. - The Short Too Complex message: indicates that a specific determination of which lines are shorted could not be made. - is caused by more than three drivers being shorted in the same direction. For example, four drivers all shorted to ground, or two or more drivers shorted with at least one driver shorted to ignition/battery and one driver shorted to ground. - Messages displaying: XXX Driver/Circuit Shorted to Ignition/ Battery will set on a per-driver basis. - XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. - the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together.When the test returns passed, then troubleshooting should proceed to clearing faults and running the HVAC Door Recalibration system test as a final check of system health. Instrument Cluster The Instrument Cluster receives and sends messages to other modules via the PCI bus circuit. The indicator lamps will illuminate briefly for a bulb check when the ignition is turned from off to run. All of the gauges receive their information via the PCI bus from the powertrain control module and body control module. The gauges and the LEDs are not individually replaceable thereby requiring complete replacement of the Instrument Cluster if a repair is necessary. In the event that the Instrument Cluster loses communication with other modules on the PCI bus, the cluster will display no bus in the VF display. The Trip/Reset button is used to switch the display from trip to total mileage. Holding the button when the display is in the trip mode will reset the trip Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4058 mileage. This button is also used to put the cluster into self-diagnostic mode. The odometer display uses blue-green vacuum fluorescent digital characters. On base models, the Instrument Cluster has three gauges: Speedometer, fuel and temperature.A red dot appears through openings in the Instrument Cluster face (P-R-N-D-2-1) to indicate the gear selected. With other models, the Instrument Cluster may also include a tachometer and use a vacuum fluorescent shift indicator. The high-line Instrument Cluster features Electroluminescent Illumination of the gauge faces (EL Panel). This feature eliminates the use of bulbs for ,gauge/panel lighting. In a manner similar to fluorescent lights, a/c voltage from an inverter integrated circuit chip is applied to the phosphorescent material, causing it to glow. The phosphorescent material is screen-printed onto flexible Mylar sheets that form the gauge faces. The odometer display and door/liftgate ajar indicators turn on when a door is opened to assist both the customer and service technician to view the odometer without turning the ignition on. On models with AutoStick, the display includes an O/D OFF indicator that is illuminated when the driver presses the Overdrive Off button on the transaxle shifter. INSTRUMENT CLUSTER SELF TEST 1. Depress and hold the Odometer Reset button. 2. Turn the ignition switch to on. 3. Release the Odometer reset button. The Instrument Cluster will illuminate all indicators and step the gauges through several calibration points.Also, the odometer will display any stored codes that may have set. Interior Lighting COURTESY LAMP CONTROL The body controller has direct control over all of the vehicle's courtesy lamps. The body computer will illuminate the courtesy lamps under any of the following conditions: 1. Any door ajar and courtesy lamp switch on the headlamp switch is not in the dome off position. 2. The courtesy lamp switch on the headlamp switch is in the dome on position. 3. A Remote Keyless Entry unlock message is received. 4. Driver door unlocked with key (with VTSS only). ILLUMINATED ENTRY Illuminated entry will be initiated when the customer enters the vehicle by unlocking the doors with the key fob, or with the key if the vehicle is equipped with vehicle theft alarm. Upon exiting the vehicle, if the lock button is pressed with a door open, illuminated entry will cancel when the door closes. If the doors are closed and the ignition switch is turned on, the illuminated entry also cancels. The illuminated entry feature will not operate if the courtesy lamp switch is in the dome off position. INTERIOR LIGHTING BATTERY SAVER If any of the interior lamps are left on after the ignition is turned off, the BCM will turn them off after 8 minutes. To return to normal operation, the courtesy lamps will operate after the dome lamp switch or door ajar switch changes state. The glove box and switched reading lamps require that the ignition be turned to the on/acc position. Memory System The memory system consists of power driver's seat, power mirror, adjustable pedals and radio presets. The Memory Seat/Mirror/Adjustable Pedals Module (MSMAPM) is located under the driver's seat. It receives input from the following: driver's manual 8-way seat switch, driver's seat position sensors, PCI bus circuits, and the power mirror sensors. The module uses these inputs to perform the following functions: position the driver's memory seat, both exterior mirrors (during recalls), both pedals, and send/receive the memory system information over the PCI bus. The Memory Set Switch is wired to the Body Control Module (BCM). A button (either #1 or #2) pressed on the set switch causes the BCM to send a message to the MSMAPM which in turn will send a motion status message back to the BCM. If the message from the MSMAPM indicates no current motion, the BCM will send a recal message to the module. The MSMAPM will set the seat, exterior mirror, pedals, and radio to the presets for the indicated driver. If any one of the memory controlled systems is inoperative from its manual switch, use the schematics and diagnostic information to correct the concern. This manual addresses the memory problems only and it is assumed there is not a basic component failure. POWER SEAT The memory power seat provides the driver with 2 position settings for the driver's seat. Each power seat motor is connected to the MSMAPM with two motor drive circuits. Each circuit is switched between battery and ground. By being able to bidirectionally drive the circuits, the MSMAPM controls the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4059 movement of the motors based on input from the power seat switch or from the position sensors when performing a memory recall. Each motor contains a potentiometer to monitor the seat position. To monitor the position of the motor, the MSMAPM sends out a 5-volt reference on the sensor supply circuit.The sensor is grounded back to the module on a common ground circuit. Based on the position of the sensor, the MSMAPM monitors the voltage change through the sensor on a separate signal circuit. The MSMAPM stores the input value of each of the four seat potentiometers in memory when the system requests a set. The driver can initiate a memory recall, using either the door mounted memory switch or the RKE transmitter (if the remote linked to memory feature is enabled via the EVIC). When initiated, the MSMAPM adjusts the four seat sensors (by using the motors) to match the memorized seat position data. For safety, the memory seat recall is disabled by the MSMAPM when the vehicle is out of park position or if the speed is not zero. Any obstruction to seat movement over a 2-second delay will cause the seat to stop moving in which case a stalled motor would be detected by the MSMAPM and the corresponding seat output would be deactivated. However, if the object obstructing the seat is removed, the seat will function normally again. MEMORY MIRROR The driver side view mirror contains vertical and horizontal bi-directional drive positioning motors and position sensors. The MSMAPM provides a 5-volt reference on the signal circuit to each position sensor. The sensors share a common ground circuit. The MSMAPM monitors the position of the mirror motors by measuring the voltage on each signal circuit. When a memory position is set, the MSMAPM monitors and stores the position of the outside mirror. The MSMAPM adjusts the mirror to the appropriate positions when a memory recall message is received from the RKE or is requested from the memory set switch. The power mirror switch during non-memory operation operates the mirror independently of the MSMAPM. Overhead Console COMPASS/TEMPERATURE MODULE, COMPASS/MINI-TRIP COMPUTER or ELECTRONIC VEHICLE INFORMATION CENTER The Compass/Temperature Module (CT), Compass/Mini-Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) is located in the overhead console. The CT provides the vehicle operator with only outdoor temperature and the compass heading. The CMTC or EVIC supplements the standard vehicle instrumentation. The CMTC and EVIC use a vacuum fluorescent (VF) display to supply the vehicle operator with a compass heading, outdoor temperature, average fuel economy, distance to empty, trip odometer, elapsed ignition on time, distance to service, warning messages, and service messages. The difference between a CMTC and an EVIC is that only the EVIC provides additional memory, feature programming, and warning messages. The EVIC is capable of displaying warning messages and memory system messages when the vehicle is equipped with memory systems. The EVIC also provides the interface to enable and disable vehicle programmable features when the vehicle is equipped with certain features. If equipped, the EVIC is also available with an integrated Universal Garage Door Opener (UGDO) known as HomeLink(R). The EVIC may also be equipped with up to 4 power door switches: ON/ OFF, Left Sliding Door, Right Sliding Door, and Liftgate. The CT function buttons are labeled C/T and US/M. The CMTC function buttons are labeled US/M, C/T, RESET, and STEP. The EVIC function buttons are labeled C/T, RESET, STEP, and MENU. The three UGDO buttons are labeled with dots to indicate the channel number. The BCM supplies most of the information displayed by the CMTC/EVIC. Display information, except for the internal compass function, is received over the PCI bus. The FCM supplies the ambient temperature sensor information via the PCI bus. The CMTC/EVIC sends and receives data over the PCI bus, communicating with the BCM, PCM, FCM, and the Instrument Cluster. Tire Pressure Monitoring System information is received from the SKREEM via PCI bus information. The tire pressure sensors are mounted to the vehicle wheels. For complete information, refer to the Tire Pressure Monitoring System section. VEHICLE INFORMATION DISPLAY The CMTC/EVIC provides the following functions: - Compass direction - Outside temperature - Elapsed ignition on time - Distance to empty - Average fuel economy - Trip odometer - Distance to service The EVIC will also display the following driver alert messages: - TURN SIGNAL ON (with vehicle graphic) - PERFORM SERVICE - DOOR OPEN (individual or multiple doors, with graphic) - LOW TIRE PRESSURE (when equipped) - ADJUSTABLE PEDAL DISABLED CRUISE ENGAGED (when equipped) - ADJUSTABLE PEDAL DISABLED VEHICLE IN REVERSE (when equipped) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4060 An audible chime or chimes will accompany any displayed warning messages. Chime requests with an OPEN message are dependent upon vehicle speed. The CT/CMTC/EVIC will not display information for any of the screens for which it did not receive the proper PCI bus data. Refer to the symptom list in the Overhead Console section for problems related to the CT/CMTC/EVIC. The CMTC/EVIC receives the following messages from the Body Control Module (BCM): - Verification of US/Metric status - VF display dimming brightness and exterior lamp status - Elapsed Ignition On Time data - Average Fuel Economy - Distance to Empty - Distance to service - Driver warning messages The CT/CMTC/EVIC receives the following messages from the Front Control Module (FCM): - Outside Temperature The CMTC/EVIC receives the following messages from the Powertrain Control Module (PCM): - Trip Odometer data - Vehicle Speed The EVIC receives the following messages from the Adjustable Pedal System Module (APS): - APS status warnings The CT/CMTC/EVIC receives the following messages from the Sentry Key Remote Electronic Entry Module (SKREEM): - Tire Pressure information The CMTC/EVIC transmits the following messages to the BCM: - Status Request: Beep, Reset, US/M Toggle - Current Display STEP BUTTON The STEP Button can be used in one of the following three ways: 1. To sequentially select one of seven displays or blank display in the following order: - Average Fuel Economy - Distance to Empty - Trip Odometer - Time Elapsed - Distance to Service Message - Off (Blank) 2. To set the magnetic variance zone when VARIANCE = X (X = 1 - 15) is indicated in the VF Display. 3. To select the displayed programmable feature setting. (When equipped.) MENU BUTTON (EVIC only) For complete information of the programmable features and memory messages. Use the MENU button to sequentially step the EVIC through the programmable features. MENU BUTTON (EVIC only) For complete information of the programmable features and memory messages.Use the MENU button to sequentially step the EVIC through the programmable features. RESET BUTTON The RESET Button has two different functions: 1. To clear the trip functions that may be reset 2. To enter and exit the diagnostic mode Pressing the RESET button once will clear the trip function that is currently being displayed (except Distance to Service) and the CMTC/EVIC will send a PCI bus beep request to the BCM. If the RESET button is pressed again within 3 seconds, the CMTC/EVIC will reset ALL of the trip functions and an additional beep request is sent to the BCM. The trip functions that may be reset are: - Average Fuel Economy - Trip Odometer - Elapsed Time Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4061 A reset will only occur if one of the trip functions that may be reset is currently being displayed. Pressing the RESET button for more than three (3) seconds resets the Distance to Service function while the Distance to Service message is being displayed. The CMTC/EVIC module will send a beep request to the BCM. Simultaneously pressing the RESET button and the STEP button while turning the ignition from Off to On will enter the CMTC/EVIC into the self-diagnostic mode. COMPASS/TEMPERATURE (C/T) BUTTON Actuating the Compass/Temperature Button (C/T) will cause the CMTC/EVIC to display the compass and temperature information. This function will operate from another traveler display or from the programmable feature mode. TRAVELER DISPLAY FUNCTIONS Using the STEP button will change the CMTC/ EVIC between modes of operation and display the appropriate information according to data received from the PCI Bus. COMPASS/TEMPERATURE The CMTC/EVIC simultaneously displays the compass reading and the outside temperature. Outside temperature information is received via the PCI bus from the FCM. The CMTC/EVIC module internally senses and calculates the compass direction. COMPASS OPERATION - ALL Upon ignition on, if the calibration information stored in the CMTC memory is within the normal range, the CMTC will perform in slow Auto-Cal mode. In slow Auto-Cal mode, the CMTC continuously compensates for the slowly changing magnetic field of the vehicle. The compass module detects changes in the vehicle magnetism and makes appropriate internal corrections to ensure proper displayed direction. However, if the calibration information stored in the CMTC memory is not within the normal range at ignition on, the CMTC will enter fast Auto-Cal. CAL is displayed along with the temperature. Auto activation of the fast Auto-Cal mode will also occur when the CMTC is subjected to high magnetic field strength levels, which cause all compass readings to be erroneous for a continuous period of five (5) minutes. During fast Auto-Cal, CAL will be displayed along with the temperature. Fast Auto-Cal can also be performed manually, by pressing and holding the RESET button for 10 seconds during the Compass/Temperature display mode. SETTING MAGNETIC ZONE VARIANCE Variance is the difference between magnetic North and geographic North. For proper compass function, the correct variance zone must be set. Refer to the Zone Variance map for the correct zone. Follow these steps to check or change the variance zone: CMTC/EVIC: - The ignition switch must be in the On position and the CMTC/EVIC display must not be blank. - If the compass/temperature data is not currently being displayed, momentarily press and release the C/T button to display compass/temp information. - Press and hold the RESET button (approximately 5 seconds) until VARIANCE = XX is displayed. The CMTC/EVIC will display the variance zone stored in memory and the word VARIANCE. - Use the RESET button to select the proper variance zone number, 1 through 15. - After selecting the proper zone number, momentarily press and release the RESET button. The variance zone is then stored in the memory and the CMTC/EVIC returns to normal operation. CT: - The ignition switch must be in the On position and the C/T display must not be blank. Press and hold the C/T and US/M buttons (approximately 5 seconds) until VARIANCE = XX is displayed. The C/T will display the variance zone stored in memory and the word VARIANCE. - Use the US/M button to select the proper variance zone number, 1 through 15. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4062 - After selecting the proper zone number, momentarily press and release the C/T button. The variance zone is then stored in the memory and the C/T returns to normal operation. COMPASS CALIBRATION The compass module has 2 types of auto calibration; slow-cal and fast-cal. Slow-cal ensures that during normal vehicle operation th0e compass performs auto-calibration functions to keep the compass sensors in their proper operating range. Whenever the ignition is On and the CT/CMTC/ EVIC receives PCI bus data indicating that engine RPM is greater than zero, auto-calibration is performed continuously. If the calibration information stored in the compass module memory is not within the normal range after a power-up cycle, the compass will display CAL. The CT/CMTC/EVIC will enter into the fast-cal mode until calibration is complete. To enter the compass into Manual Calibration mode, perform the following steps: - Drive the vehicle to an area away from any large metal objects or overhead power lines. - Ensure that the proper variance zone is selected. See "Setting Magnetic Zone Variance". - The ignition switch must be in the On position and the CMTC/EVIC display must not be blank. - Press the C/T button to view the Compass/ Temperature display. - Press and hold the RESET button (approximately 10 seconds) until CAL is displayed, then release the button. - Drive slowly, less than 5 MPH (8 KPH) in at least 1 complete 360-degree circle. - CAL will remain illuminated to alert the driver that the compass is in the calibration mode. - After calibration is complete, CAL will turn off. NOTE: For C/T Manual Calibration, perform the same procedure as above, but press and hold the C/T and US/M buttons until CAL is displayed. If the compass appears blank, unable to be calibrated, or the compass displays false indications,the vehicle must be demagnetized. SELF-CHECK DIAGNOSTICS The CT/CMTC/EVIC is capable of performing a diagnostic self check on its internal functions. Diagnostics may be performed using a DRBIII(R) or by using the following procedure: 1. For CMTC/EVIC: With the ignition switch in the OFF position, depress and hold the RESET and the STEP buttons. For CT: With the ignition switch in the OFF position, depress and hold the C/T and the US/M buttons. 2. Turn the ignition switch to the ON position. 3. Continue to hold both buttons until the software versions are displayed, then release the buttons. 4. All of the VFD segments will illuminate for 2-4 seconds. Check for segments that do not illuminate or illuminate all the time. 5. When the self-check is complete the EVIC will display one of the following messages: - PASS SELF TEST - FAILED SELF TEST - NOT RECEIVING J1850 MESSAGE When the self-check is complete the CT/CMTC will display one of the following messages: - PASS - FAIL - BUS 1. To exit the self-check mode: For the CMTC/EVIC: Depress the STEP or RESET button, or cycle the ignition switch and the CMTC/EVIC will return to normal operation. For the C/T: Depress the C/T or US/M button, or cycle the ignition switch and the CT will return to normal operation. If a Communication fault is displayed, refer to the symptom list. If a FAIL or FAILED is displayed, the CT/CMTC/EVIC must be replaced. AMBIENT TEMPERATURE SENSOR Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4063 The ambient air temperature is monitored by the FCM and displayed by the CT/CMTC/EVIC. The FCM receives a hardwire input from the ambient temperature sensor (ATS). The ATS is a variable resistor that operates on a 5-volt reference signal circuit hardwired from the FCM. The resistance in the ATS changes as the outside temperature rises or falls. The FCM senses the change in reference voltage through the ATS resistor. Based on the resistance of the ATS, the FCM is programmed to correspond to a specific temperature. The FCM stores and filters the ambient temperature data and transmits this data to the CMTC/EVIC via the PCI Bus. The ATS cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. AMBIENT TEMPERATURE SENSOR FAULT CODES The outside temperature function is supported by the ambient temperature sensor (ATS), a signal and ground circuit hardwired to the FCM, and the CMTC/EVIC display. If the ATS sense circuit is shorted to ground, the temp display will be 54° C (130° F) to indicate SHORT circuit condition. If the ATS sense circuit is open, the temp display will be -40° C (-40° F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the CMTC/EVIC VFD can be tested. The ATS is supported by the FCM. Ambient Temperature Sensor DTC's will be recorded in the FCM. The ATS can be diagnosed using the following Sensor Test. Test the ATS circuits using the diagnostics in the Body Diagnostic Procedures Manual. If the CMTC/EVIC passes the self-test, and the ATS, the circuits, and PCI bus communications are confirmed to be OK, but the CMTC/EVIC temperature display is inoperative or incorrect, replace the FCM. AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: - 0° C (32° F) Sensor Resistance = 29.33 - 35.99 Kilohms - 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kilohms - 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kilohms - 25° C (77° F) Sensor Resistance = 9.12 - 10.86 Kilohms 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kilohms - 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance values are not OK, replace the Sensor. HOMELINK(R) UNIVERSAL TRANSMITTER If equipped, HomeLink(R) Universal Transmitter is integrated into the overhead console. For added security it will operate home security systems that use coded signals known generically as Rolling Codes. The overhead console display provides visual feedback to the driver, indicating which HomeLink(R) transmitter channel button is being pressed. The HomeLink(R) can learn and store up to three separate transmitter radio frequency codes to operate garage door openers, security gates, and security lighting. The HomeLink(R) buttons are marked with one, two, or three dots. For complete information. TIRE PRESSURE MONITORING SYSTEM (TPMS) If equipped with the Tire Pressure Monitoring System (TPMS), each of the vehicles four wheels will have a valve stem with a pressure sensor and radio transmitter built in. Signals from the tire pressure Sensor/Transmitter are received and interpreted by the Sentry Key Remote Entry Module (SKREEM). Using the DRBIII(R), go to ANTI-THEFT for the SKREEM data. A Sensor/Transmitter in a mounted wheel will broadcast an RF frequency indicating its pressure once per minute when the vehicle is in drive mode. To activate the Sensor/Transmitter operation, the required SKREEM speed is 13 mph (20 km/h). Each Sensor/Transmitters broadcast is uniquely coded so that the SKREEM can monitor the states of each Sensor/Transmitter on the vehicle. The SKREEM TPMS does not use a magnet to relearn, it automatically learns while driving after a SKREEM or a Sensor/Transmitter has been replaced. TRAINING THE SKREEM If a Sensor/Transmitter is replaced, the vehicle has to be parked for at least 15 minutes for the system to be ready to learn the new Sensor/Transmitter ID code. The vehicle then must be driven for a minimum of five minutes with a minimum continuous speed above 13 mph (20 km/h). The system will learn the new Sensor/Transmitter and clear the DTC's automatically. The Sensor/ Transmitters are programmed at the assembly plant in this clockwise orientation: Sensor/Transmitter 1 = Left Front Sensor/Transmitter 2 = Right Front Sensor/Transmitter 3 = Right Rear Sensor/Transmitter 4 = Left Rear NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4064 1. If one or all Sensor/Transmitters cannot be trained, check for and avoid RF interference. 2. If one Sensor/Transmitter still cannot be trained, replace it and retry. 3. If all Sensor/Transmitters still fail to train, replace the SKREEM. PRESSURE THRESHOLDS The SKREEM will monitor the tire pressure signals from the Sensor/Transmitters and determine if any tire has gone below the low-pressure or above the high-pressure thresholds. Refer to the tables below: Low Tire Pressure Thresholds High Tire Pressure Thresholds *Tolerance ±6.9 kPa (1 PSI) ACTIVE FAULT AND SYSTEM ALERTS An active fault will be triggered when a system failure has been detected. When this occurs, the Instrument Cluster will illuminate the TPMS indicator and the SKREEM will store the fault code. An alert will be triggered when a tire pressure has gone below or above the set threshold pressure. When this occurs, the Instrument Cluster will flash the TPMS indicator. The SKREEM will request a secondary message to be displayed on the EVIC (if equipped). Only when a tire pressure has gone below the set threshold pressure will the SKREEM request the TPMS indicator to flash and display the EVIC message (if equipped). When a high pressure alert occurs, only the EVIC message will be displayed. This action will be displayed as long as the alert condition is active. Park Assist System The Park Assist System display activates an audible tone that changes from intermittent to continuous as the final two Light Emitting Diodes (LED's) are illuminated on one side or both sides of the display. The system detection length from the rear of the vehicle is 0.3 meters to 1.5 meters. This area extends around the rear side of the vehicle.The system detection height from the ground is 0.2 meters to about 1.5 meters. The radio mutes when the system activates its audible tone. When the driver selects Reverse or Neutral the system scans for objects behind the vehicle using four sensors located in the rear bumper. Objects can be detected from up to 1.5 meters. A warning display above the rear window provides both visible and audible warnings indicating the range of the object. The system is active only when the vehicle is in reverse or neutral for vehicle speeds less than 16 Km/h (10 mph). If the vehicles Parking/Emergency Brake is applied, the system is deactivated. The display contains two sets of yellow and red Light Emitting Diode's (LED's) that the driver can see in the rear view mirror. Each side of the vehicle has its own warning LED's. The system provides a visual warning by illuminating one or more yellow LED's as the vehicle gets closer to the object. As the vehicle continues to approaches the object, one red LED is illuminated and the system emits a series of short beeps. The tone will remain constant and both red LED's are illuminated once the vehicle is within 12 inches (30.5 cm) of the object. The system can be turned ON or OFF through the Electronic Vehicle Information Center (EVIC) when the vehicle is in PARK. If the park assist system is turned OFF, a single chime will sound and the EVIC will display the following message REAR PARK ASSIST OFF, when the vehicle is in reverse. - Ensure that the rear bumper is free of dirt and debris to keep the system operating properly. - Jackhammers, large trucks, and other vibrations could affect the performance of the system. - Ensure that the parking brake is not applied. If Service Park Assist System appears in the EVIC after making sure the rear bumper is clean, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4065 proceed to diagnose the system using a scan tool and the appropriate diagnostic information. Power Door Lock System When the BCM receives input for a lock request from a door lock switch, RKE or cylinder lock switch (only with VTSS), it will turn the lock drivers on for a specified time of 375 msec. If the request is there beyond 375 msec, the BCM considers the door lock signal stuck. Once a door lock or unlock signal is stuck for longer than 10 seconds, the BCM will set a trouble code and the signal input is ignored until the stuck condition disappears. The door lock switches provide a variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond to that command. DOOR LOCK INHIBIT When the key is in the ignition and in any position and either front door is open, the door lock switches LOCK functions are disabled. The UNLOCK functions are still functional. This protects against locking the vehicle with the keys still in the ignition. The RKE key fob will still lock the doors as usual. After the key is removed from the ignition or the doors are closed, the power door locks will operate normally. AUTOMATIC DOOR LOCKS This feature can be enabled or disabled by using either the DRBIII(R) or the customer programming method. When enabled all the doors will lock when the vehicle reaches a speed greater than 18 MPH (29 KMH) and all the doors are closed. If a door is opened and the vehicle slows to below 18 MPH (29 KMH), the door locks will operate again once all doors are closed and the speed is above 18 MPH (29 KMH). REMOTE KEYLESS ENTRY (RKE) The RKE transmitter uses radio frequency signals to communicate with the SKREEM module. The SKREEM is on the PCI bus. When the operator presses a button on the transmitter, it sends a specific request to the SKREEM. In turn the SKREEM sends the appropriate request over the PCI Bus to the: - Body Control Module (BCM) to control the door lock and unlock functions, the arming and disarming of the Vehicle Theft Security System (if equipped), and the activation of illuminated entry. - Integrated Power Module (IPM) to activate the park lamps, the headlamps, and the horn for horn chirp. - Power Liftgate Module (PLGM) to control the liftgate operation (double press). - Power Sliding Door Module (PSDM) to control the sliding door operation (double press). After pressing the lock button on the RKE transmitter, all of the door locks will lock, the illuminated entry will turn off (providing all doors are closed), and the vehicle theft security system (if equipped) will arm. After pressing the unlock button, on the RKE transmitter, one time, the driver doorlock will unlock, the illuminated entry will turn on the courtesy lamps, and the vehicle theft security system system (if equipped) will disarm. After pressing the unlock button a second time, the remaining door locks will unlock. The EVIC or the DRBIII(R) can reprogram this feature to unlock all of the door locks with one press of the unlock button. If the vehicle is equipped with the memory system, the memory message will identify which transmitter (1 or 2) sent the signal. The SKREEM is capable of retaining up to 8 individual access codes (8 transmitters). If the PRNDL is in any position except park, the SKREEM will disable the RKE. The 3 or 6 button transmitter uses 1-CR2032 battery. The minimum battery life is approximately 5 years based on 20 transmissions a day at 84° F (25° C). Use the DRBIII(R) or the Miller Tool 9001 RF Detector to test the RKE transmitter. Use the DRBIII(R) or the customer programming method to program the RKE system. However, the SKREEM will only allow RKE programming when the ignition is in the on position, the PRNDL is in park position, and the VTSS (if equipped) is disarmed. PANIC FUNCTION Pressing the panic button on the RKE transmitter will cause the headlamp relay, the park lamp relay, and the horn relay to pulsate, which in turn will cause the exterior lamps to flash and the horn to sound intermittently. It will also cause the courtesy lamp relay to actuate, turning on the courtesy lamps. Pressing the panic button again stops the headlamps and the park lamps from flashing and the horn from sounding. However, the courtesy lamps will remain on until either the BCM times out lamp operation or until the ignition is turned on. The panic feature operates for three minutes at a time, unless the operator cancels it, or the ignition is turned on. Actuating the headlamp, horn, park lamps, and courtesy lamps with the DRBIII(R) will verify if the circuits and the Integrated Power Module are OK. If the panic feature is still inoperable with all transmitters, it will be necessary to replace the SKREEM. If the function is inoperable with just one transmitter, then replace only that transmitter. ROLLING CODE The rolling code feature changes part of the transmitter message each time that it is used. The transmitter message and the receiver message increment together. Under certain conditions with a rolling code system (pressing a button on the RKE transmitter over 255 times outside the receiver range, battery replacement, etc.), the receiver and transmitter can fall out of synchronization. NOTE: The lock function works from the RKE transmitter even in an out of synchronization condition and therefore it could be verified by pressing the LOCK button on the RKE integrated key. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4066 To resynchronize, press and release the UNLOCK button on the RKE transmitter repeatedly (it may take up to eight cycles) while listening carefully for the power door locks in the vehicle to cycle, indicating that resynchronization has occurred. PROGRAMMABLE DOOR LOCK FEATURES - The RKE can be changed to unlock all doors with one press - The Automatic Door Locks can be enabled/ disabled - Auto Unlock on Exit can be enabled/disabled - RKE horn chirp on lock can be enabled/disabled - RKE optical chirp (turn signal lamps) can be enabled/disabled - Program a new RKE transmitter. - RKE linked to memory (if equipped with memory system) enabled/disabled (DRBIII(R) only). Allows memory to be operable only from the driver door switch. Rear Window Defog/Heated Mirror The defroster button located on the HVAC control controls the rear window defogger and the heated side view mirrors. When the defroster button is pushed, the HVAC control sends a bus message over the PCI bus to the Front Control Module (FCM) which controls the Rear Window Defogger relay. The defroster LED will illuminate when the defroster function is on. The defroster will function for 10 minutes or can be cycled off sooner by pressing the defroster button again. Vehicle Theft Security System The Vehicle Theft Security System (VTSS) is part of the Body Control Module (BCM). The BCM monitors the vehicle doors, liftgate (export only), hood (export only), and the ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps and the VTSS indicator lamp. The VTSS does not prevent engine operation, this is done with the Sentry Key Remote Entry Module (SKREEM). The VTSS indicator lamp will flash for approximately 15 seconds during the arming process. If there is no interruption during the arming process, upon completion the VTSS indicator lamp will flash at a slower rate. When the BCM receives an input to trigger the alarm, the BCM will control the outputs of the headlamps, horn, and VTSS lamp for approximately 15 minutes. Arming (Active and Passive) Active arming occurs when the ignition key is removed, the RKE transmitter or door key cylinders are used to lock the vehicle doors, whether the doors are open or closed. The arming process is complete only after all doors are closed. Passive arming occurs when the ignition key is removed, the driver door is opened, and the doors are locked with the power door lock switch, and the door is closed. Disarming (Active and Passive) Active disarming occurs when the RKE transmitter is used to unlock the vehicle doors. This disarming will also halt the alarm once it has been activated. Passive disarming occurs upon normal vehicle entry (unlocking driver door with the key) or turning the ignition switch on with a valid ignition key. This disarming will also halt the alarm once it has been activated. Tamper Alert The VTSS tamper alert will sound the horn three times upon disarming after an initial alarming has occurred to indicate a tamper condition has occurred. Manual Override The system will not arm if the doors are locked using the manual lock control or if the locks are actuated by an inside occupant after the doors are closed. Diagnosis For complaints about the Vehicle Theft Alarm triggering on its own, use the DRBIII(R) and read the Last VTSS Cause status. Arming Before arming, all doors, liftgate, and the hood must be completely closed. The system can only be armed by locking the doors with the RKE transmitter. Disarming To disarm the alarm system, use the RKE transmitter or turn the ignition on with a valid ignition key. This will also halt the alarm once it has been activated. NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes on after ignition on and stays on, the PCI Bus Communication with the powertrain Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4067 control module has possibly been lost. Power Folding Mirrors The power folding mirrors are powered to two positions: folded and unfolded. The driver may choose fold or unfold with a switch that is located on the right side of the steering column. The folding mirror switch grounds a sense wire that comes from the Body Control Module when it is placed in the fold position. The mirrors will move to the position designated by the switch whether the ignition switch is the On or Off position and both front doors are closed. When the Power Folding Mirror switch is left in the fold position during a vehicle exit the mirrors will automatically unfold then refold after both front doors are closed. This is to prevent mirror contact with either front door when opened. When opening either front door, the Body Control Module will unfold the mirrors in the following manner depending on which front door is opened. If the driver door is opened, only the driver side mirror will unfold. If the passenger door is opened, both mirrors will unfold. The passenger mirror is prevented from unfolding when the driver's door is opened by the Passenger Folding Mirror Relay, which opens the driver circuit to the passenger side mirror. Power Liftgate System POWER LIFTGATE The power liftgate (PLG) system is activated through the use of the following: remote keyless entry (RKE), overhead console switches, outside liftgate handle switch or the DRBIII(R). These inputs are hardwired to the body control module (BCM) and can be monitored with a diagnostic tool. The BCM will send the message via PCI bus to the power liftgate module (PLGM). The liftgate must be in the full open or full closed position to operate. Once the BCM sends a button activation message to the PLGM, the module shall read all inputs, outputs and vehicle conditions to determine whether it shall open, close or inhibit the PLG operation. Once the PLGM determines the vehicle conditions are safe for operation, the PLGM will initiate a chime for 2 seconds prior to the liftgate activation and 2 seconds during the open or close cycle. During an opening or closing cycle, the PLGM can detect an obstacle present should it meet sufficient resistance by the hall effect sensors (integrated in the gear motor assembly GMA).During an open cycle, multiple liftgate activations (RKE, overhead console, B pillar) are ignored until the liftgate reaches the full open position. However, during a close cycle, a 2nd liftgate activation (RKE, overhead console, B pillar) will reverse the liftgate to the full open position. If the engine is cranked during a power open/close the PLG will pause then resume after engine cranking. In addition, if the vehicle is placed in gear during an open cycle, the PLG shall reverse direction and begin closing. If the vehicle is placed in gear during a closing cycle, the PLG shall continue closing until fully closed. If the outside handle is activated during an open cycle, the PLG will become a full manual liftgate. If the outside handle is activated during a close cycle, the PLG shall reverse direction of travel to the full open position. DIAGNOSTIC FEATURES The PLG can be flashed on vehicle via PCI bus with a DRBIII(R) diagnostic tool. The DRBIII(R) can read all inputs, actuate all outputs, read module information, and read diagnostic trouble codes. As a reminder, some DTC's can be set during normal PLG operation. SYSTEM INHIBITORS 1. Battery voltage too high or too low (above 16 V, below 9.5 V) 2. Vehicle in gear 3. Vehicle speed > 0 mph/km/h 4. Outside temperature too high, above 143° F (62° C) or too low, below -12° F (-24° C). 5. O/H console lockout will inhibit the B pillar switches only. 6. Liftgate locked will inhibit all interior switches from opening (overhead console). A locked liftgate can be power closed. 7. Pinch Sensor switch stuck shall inhibit the power close feature. Power Sliding Door System POWER SLIDING DOOR The Power Sliding Door (PSD) system is activated through the use of the following: Remote Keyless Entry (RKE), overhead console switches, B pillar switches or the DRBIII(R). These inputs are hardwired to the body control module (BCM) and can be monitored with a diagnostic tool. The BCM will send the message via PCI bus to the power sliding door module (PSDM). The sliding door must be in the full open or full closed position to operate. Once the BCM sends a button activation message to the PSDM, the module shall read all inputs, outputs and vehicle conditions to determine whether it shall open, close or inhibit the PSD operation. During an opening or closing cycle, the PSDM can detect an obstacle present should it meet sufficient resistance by the hall effect sensors (integrated in the drive motor). During an open cycle, multiple door activations (RKE, overhead console, B pillar) are ignored until the door reaches the full open position. However, during a close cycle, a 2nd door activation (RKE, overhead console, B pillar) will reverse the door to the full open position. If the engine is cranked during a power open/close the PSD will pause then resume after engine cranking. In addition, if the vehicle is placed in gear during an open cycle, the PSD shall reverse direction and begin closing. If the vehicle is placed in gear during a closing cycle, the PSD shall continue closing until fully closed. If the inside or outside handle is activated during an open or close cycle, the PSD will become a full manual sliding door. The child lockout is mechanical only and has no effect on the B-pillar switch as it did in previous models. There is only one part number for the power sliding door module (PSDM). The driver sliding door harness has an additional ground circuit which will Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4068 identify it as the driver side. This eliminates the need for a left and a right side module. DIAGNOSTIC FEATURES The PSDM can be flashed on vehicle via PCI bus with a DRBIII(R) diagnostic tool. The DRBIII(R) can read all inputs, actuate all outputs, read module information, and read diagnostic trouble codes. As a reminder, some DTC's can be set during normal PSD operation. SYSTEM INHIBITORS 1. Battery voltage too high or too low (above 16 V, below 9.5 V) 2. Vehicle in gear 3. Vehicle speed > 0 mph/km/h 4. O/H console lockout will inhibit the B pillar switches 5. Doors locked will inhibit all interior switches from opening (Overhead Console, B Pillar). A locked sliding door can be power closed. Wiper System FRONT WIPER The front wiper/washer system consists of the following features: lo-hi-speed, mist wipers, intermittent wipers and wipe after wash. The front wiper system is only active when the ignition switch is in the RUN/ACC position. The vehicle operator selects the front wiper function using the front wiper switch (a resistive multiplexed stalk switch) which is integral to the Multi-Function Switch. The front wiper switch is hardwired to the Body Control Module (BCM). Upon receiving a wiper switch signal, the BCM sends a PCI Bus message to the Front Control Module (FCM). The FCM controls the ON/ OFF relay, the HIGH/LOW relay and the front and rear washer pump motors. The Wiper system utilizes the BCM to control the on/off and hi/low relays for the low and hi speed wiper functions, intermittent wiper delay as the switch position changes, pulse wipe, wipe after wash mode and wiper motor functions. The BCM uses the vehicle speed input to double the usual delay time below 10 MPH (16 KPH). SPEED SENSITIVE INTERMITTENT WIPE MODE There are 5 individual delay time settings with a minimum delay of 1.7 seconds to a maximum of 18.4 seconds. When the vehicle speed is under 10 MPH (16 KPH), the delay time is doubled, providing a delay range of 3.4 seconds to 36.8 seconds. PULSE WIPE When the wiper is in the off position and the driver presses the wash button for more than 0.062 seconds, but less than 0.5 seconds,2 wipe cycles in low speed mode will be provided. PARK AFTER IGNITION OFF Because the wiper relays are powered from the battery, the BCM can run the wipers to park after the ignition is turned off. WIPE AFTER WASH When the driver presses the wash button for over 0.5 seconds and releases it, the wiper will continue to run for 2 additional wipe cycles. REAR WIPER The rear wiper/washer system consists of the following features: mist wipers, intermittent wipers and wipe after wash. The rear wiper system is only active when the ignition switch is in the RUN/ACC position. The vehicle operator selects the rear wiper function using one of the three buttons on the dash mounted rear wiper switch. The rear wiper switch is hardwired to the Body Control Module (BCM). Upon receiving a wiper switch signal, the BCM provides 12 volts to the rear wiper motor. Rear washer occurs when the BCM receives a rear washer switch ON input. The BCM sends a PCI Bus message to the FCM requesting rear washer on. The FCM activates the rear washer by providing a ground for the rear washer motor. SPEED SENSITIVE INTERMITTENT WIPE MODE The delay setting of the rear wiper system is based solely on the vehicle speed. The delay time is defined as the amount of time from the start of a wipe to the beginning of the next wipe. The rear wiper system delay time is based on the following: 7.75 - (MPH x 0.05) = Seconds delay Examples:At zero (0) MPH the delay is 7.75 seconds. At 100 MPH the delay is 2.75 seconds. WIPE AFTER WASH When the driver presses the wash button for over 1.5 seconds and releases it,the wiper will continue to run for 2 additional wipe cycles. Telecommunications HANDS FREE PHONE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 4069 OVERVIEW The vehicle telecommunications system consists of a Hands Free Module, Rear View Mirror, and a Blue-tooth Hands Free Profile enabled cell phone. The system allows vehicle occupants to use voice recognition technology to make, receive and screen phone calls without physically handling a cell phone. The system has a programmable phone book that can prevent the vehicle operator from becoming distracted searching for a specific number. Seven different wireless phones can be programmed to operate each individual system. Each of the seven phones is given a rank of priority when programmed. OPERATION Incoming phone messages are transmitted to the vehicle occupants through the vehicles audio system when the ignition is on and the wireless phone is on. Upon receiving the signal from an incoming phone call, the vehicle audio system will fade out the current CD/DVD or radio output. The vehicle occupants are then directed to accept or reject the call.Outgoing audio messages are received through the microphone located in the rearview mirror then transmitted via hardwire to the Hands Free Module and finally transmitted through the wireless phone. Volume of the voice prompts and incoming conversation is controlled using the vehicles radio audio controls and steering wheel controls if equipped. The rear view mirror contains a Phone Switch, Voice Recognition Switch and a microphone. The rear view mirror transmits these inputs via hardwired circuits to the Hands Free Module. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Air Bag System Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Any Station Preset Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4072 Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4073 POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Test 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4074 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Pause/Play Switch Inoperative Test 1 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4075 Test 1 SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Remote Radio Controls Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4076 Test 4 - 7 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4077 Test 8 - 9 SYMPTOM REMOTE RADIO CONTROLS INOPERATIVE POSSIBLE CAUSES - Open radio control MUX circuit at the switch - Open radio control MUX return circuit at the switch - Remote radio switch - Body control module - internal short - Open clockspring - Open radio control MUX circuit - Open radio control MUX return circuit - Body control module - open internal Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4078 Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4079 POSSIBLE CAUSES - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure ATC Head LED(s)/Backlighting Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4080 Test 1 - 3 Test 4 - 5 SYMPTOM ATC HEAD LED(S)/BACK LIGHTING INOPERATIVE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4081 POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - ATC - LED(s) inoperative - ATC - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4082 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4083 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4084 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4085 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4086 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM FUSE #10 - Fused front blower motor relay output circuit shorted to ground - Blower motor shorted to ground - Front blower power module shorted to ground - Ground circuit open - Blower motor control circuit shorted to voltage - Blower motor control circuit open - Front blower power module open - Automatic temperature control module open - Check blower motor operation - Front blower power module open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4087 Test 1 Test 2 SYMPTOM FRONT BLOWER RUNS AT ONLY ONE SPEED Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4088 POSSIBLE CAUSES - Blower motor control circuit shorted to ground - Automatic temperature control module - Front blower power module HVAC System Test Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4089 Test 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4090 Test 6 Test 7 SYMPTOM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4091 HVAC SYSTEM TEST POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active ATC DTC's - Check for AC cooldown test fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear ATC Switch LED(s)/Backlighting Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4092 Test 4 - 5 SYMPTOM REAR ATC SWITCH LED(S)/BACK LIGHTING INOPERATIVE POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - Rear ATC switch - LED(s) inoperative - Rear ATC switch - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4093 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4094 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4095 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4096 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4097 Test 15 - 16 SYMPTOM REAR BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM Fuse #12 - Fused rear blower relay output circuit shorted to ground - Blower motor shorted to ground - Rear blower motor power module shorted to ground - Ground circuit open - Rear blower motor control circuit shorted to voltage - Rear blower motor control circuit open - Rear blower motor power module open - Automatic temperature control module open - Check blower motor operation - Rear blower motor power module open - IPM - open circuit - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4098 Test 1 Test 2 SYMPTOM REAR BLOWER RUNS AT ONLY ONE SPEED POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4099 - Rear blower motor control circuit shorted to ground - Automatic temperature control module - Rear blower motor power module Chime Inoperative Test 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE POSSIBLE CAUSES - Use DRB to actuate chime - Chime driver circuit - open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4100 - Chime driver circuit - short to ground - Chime driver circuit - short to voltage - Instrument cluster - BCM Key In Ignition and Drivers Door Open Chime Not Operating Properly Test 1 - 3 SYMPTOM KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME NOT OPERATING PROPERLY POSSIBLE CAUSES - DRB chime actuator - Driver door ajar status - Ignition switch - Body control module Vehicle Speed Warning Chime Problem Test 1 SYMPTOM PROBLEM WITH THE VEHICLE SPEED WARNING CHIME POSSIBLE CAUSES - Incorrect country code programmed in BCM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4101 - Body control module Left Front Door Ajar Switch Sense Circuit Open Test 1 - 4 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Left front door ajar switch ground circuit open - Left front door (lock motor) ajar switch - Left front door ajar switch sense circuit open - Body control module internal malfunction Left Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4102 Test 1 - 2 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left front door (lock motor) ajar switch shorted to ground - Left front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Left Sliding Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4103 Test 1 - 3 Test 4 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Left sliding door ajar switch sense circuit open - Left sliding door ajar switch sense circuit open - Body control module internal malfunction Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4104 - Left sliding door lock motor/ajar switch (latch assy). Left Sliding Door Ajar Switch Sense Circuit Shorted to Ground Test 1 - 3 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left sliding door lock motor/ajar switch shorted to ground - Left sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Left sliding door lock motor/ajar switch (latch assy). Liftgate Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4105 Test 1 - 4 SYMPTOM LIFTGATE AJAR CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Liftgate ajar switch ground circuit open - Liftgate ajar switch (cinch/release motor) - Liftgate ajar switch sense circuit open - Body control module internal malfunction Liftgate Ajar Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4106 Test 1 - 2 SYMPTOM LIFTGATE AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Liftgate ajar switch shorted to ground - Liftgate ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4107 Test 1 - 4 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Right front door ajar switch ground circuit open - Right front door (lock motor) ajar switch - Right front door ajar switch sense circuit open - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4108 Test 1 - 2 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right front door (lock motor) ajar switch shorted to ground - Right front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Sliding Door Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4109 Test 1 - 3 Test 4 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Right sliding door ajar switch sense circuit open - Right sliding door ajar switch sense circuit open - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4110 Right Sliding Door Ajar Circuit Shorted to Ground Test 1 - 3 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right sliding door lock motor/ajar switch shorted to ground - Right sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) A/C Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4111 Test 1 - 2 Test 3 SYMPTOM A/C STATUS INDICATOR FLASHING - MTC POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Blend/Mode/Recirc Door Operation Improper -- Dual & Three-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4112 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4113 Test 4 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4114 Test 7 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4115 Test 10 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER -- DUAL & THREE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Passenger blend door actuator/linkage/door - Driver blend door actuator/linkage/door - Recirculation door actuator/linkage/door - Rear mode door actuator/linkage/door - Rear blend door actuator/linkage/door Blend/Mode/Recirc Door Operation Improper --Single-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4116 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4117 Test 4 - 7 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER --SINGLE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Blend door actuator/linkage/door - Recirculation door actuator/linkage/door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4118 Front A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Test 4 SYMPTOM FRONT A/C - HEATER CONTROL ILLUMINATION INOPERATIVE -MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - A/C - heater control module - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4119 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4120 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4121 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4122 Test 11 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4123 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #10 - Fused front blower motor relay output circuit shorted to ground - Front blower motor resistor block shorted to ground - Front blower motor resistor block shorted to ground - Blower motor - Blower motor - A/C - heater control module - Ground circuit open - Blower motor high driver circuit open - Front blower motor resistor block open - Front blower motor resistor block open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Motor Speeds Incorrect - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4124 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4125 Test 3 - 5 SYMPTOM FRONT BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Blower motor driver circuit(s) shorted to ground - Blower motor driver circuit(s) shorted to voltage - Blower motor driver circuits shorted together - A/C - heater control module - speeds incorrect - Blower motor driver circuit(s) open - Blower motor resistor block - open speed HVAC System Test - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4126 Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4127 Test 5 Test 5 SYMPTOM HVAC SYSTEM TEST - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4128 POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active HVAC DTC's and system tests fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4129 Test 4 - 5 SYMPTOM REAR A/C - HEATER CONTROL ILLUMINATION INOPERATIVE - MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - Inoperative bulb - Ground circuit open - Rear blower rear control switch - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4130 Test 1 - 2 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4131 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4132 Test 11 - 14 SYMPTOM REAR BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #12 - Fused rear blower motor relay output circuit shorted to ground - Blower motor - Ground circuit open - A/C - heater control module - Check for power to rear blower motor - Blower motor - Rear blower high speed circuit open - Rear blower motor high circuit open - Rear blower motor resistor block - IPM - open circuit Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4133 - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Motor Speeds Incorrect - MTC Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4134 Test 3 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4135 Test 6 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4136 Test 10 SYMPTOM REAR BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to ground - A/C - heater control module - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to voltage - Rear blower motor front control feed circuit shorted to voltage - Rear blower driver CKT(s) shorted to rear blower front control feed CKT - Rear blower motor driver circuits shorted together - A/C - heater control module - Rear blower motor driver circuit(s) open - Rear blower motor resistor block Rear Blower Rear Control Switch INOP In One or More Speeds - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4137 Test 1 - 2 Test 3 SYMPTOM REAR BLOWER REAR CONTROL SWITCH INOP IN ONE OR MORE SPEEDS - MTC POSSIBLE CAUSES - Rear blower motor driver circuit(s) open - Rear blower rear control switch - Rear blower motor front control feed circuit open - A/C - heater control module Recirc Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4138 Test 1 - 2 Test 3 SYMPTOM RECIRC STATUS INDICATOR FLASHING - MTC TEST NOTE This symptom is diagnosed using the test A/C STATUS INDICATOR FLASHING - MTC. POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Any PCI Bus Indicator Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4139 Test 1 - 4 SYMPTOM ANY PCI BUS INDICATOR INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - No response - instrument cluster - No response - ECM / PCM - Indicator inoperative - Instrument cluster Seat Belt Indicator Always On Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4140 Test 1 SYMPTOM SEAT BELT INDICATOR ALWAYS ON POSSIBLE CAUSES - ACM seat belt indicator command present - Instrument cluster Overhead Console Test 1 - 4 SYMPTOM REPAIRING CMTC DISPLAYS DOUBLE DASH (- - ) IN TEMP DISPLAY POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4141 - No response - PCI BUS - powertrain control module - CMTC BUS message failure - Compass mini-trip computer - Ambient temperature sensor - PCM ambient air temperature sensor DTC present - CMTC internal Left Cylinder Lock Switch Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4142 Test 4 - 5 SYMPTOM LEFT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - left cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - left cylinder lock switch MUX short to voltage Remote Keyless Entry Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4143 Test 1 - 4 Test 5 - 6 SYMPTOM REMOTE KEYLESS ENTRY INOPERATIVE POSSIBLE CAUSES - DTC present - SKREEM DTC present - Test transmitter with tester - RKE transmitter inoperative - RKE transmitter not programmed - SKREEM module - RKE inoperative - SKREEM module - RKE inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4144 Right Cylinder Lock Switch Inoperative Test 1 - 3 Test 4 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4145 SYMPTOM RIGHT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - right cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - right cylinder lock switch MUX short to voltage Power Doors - Liftgate Test 1 - 4 SYMPTOM POWER LIFTGATE INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Power Doors - Sliding Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4146 Test 1 - 4 SYMPTOM POWER SLIDING DOOR INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Alarm Trips On Its Own Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4147 Test 1 - 4 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - Last VTSS cause - Attempt to trip alarm - Intermittent condition Left Front Door Does Not Trip VTSS Test 1 SYMPTOM LEFT FRONT DOOR DOES NOT TRIP VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4148 POSSIBLE CAUSES - Body control module - Check DRBIII(R) for driver door ajar response Left Sliding Door Does Not Trip VTSS Test 1 SYMPTOM LEFT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Monitor DRBIII(R) for left sliding door ajar status - Body control module Right Front Door Does Not Trip VTSS Test 1 SYMPTOM RIGHT FRONT DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for passenger door ajar response - Body control module Right Sliding Door Does Not Trip VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4149 Test 1 SYMPTOM RIGHT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for right rear door ajar response - Body control module VTSS Will Not Arm Test 1 - 3 SYMPTOM VTSS WILL NOT ARM POSSIBLE CAUSES - Check the VTSS status - Check for BCM DTC's and VTSS arming inhibitors - Check for PCI BUS communication of instrument cluster and SKIM - Body control module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4150 Body Control Module: Component Tests and General Diagnostics Six Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation Road Testing ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. WARNING: REASSEMBLE ALL COMPONENTS BEFORE ROAD TESTING A VEHICLE. DO NOT TRY TO READ THE DRBIII(R) SCREEN OR OTHER TEST EQUIPMENT DURING A TEST DRIVE. DO NOT HANG THE DRBIII(R) OR OTHER TEST EQUIPMENT FROM THE REARVIEW MIRROR DURING A TEST DRIVE. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIII(R) OR OTHER TEST EQUIPMENT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Vehicle Preparation For Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Glossary of Terms ABS antilock brake system ACT actuator APS adjustable pedals system ATC automatic temperature control BCM body control module BPS bladder pressure sensor BTS belt tension sensor CAB controller antilock brake CMTC compass/mini-trip computer CPA connector positive assurance DAB driver airbag DCHA diesel cabin heater assist (cabin heater) DLC data link connector DTC diagnostic trouble code DR driver EBL electric back lite (rear window defogger) ECM engine control module EVIC electronic vehicle information center FCM front control module GCC Gulf Coast Countries HE hall effect HFM hands free module HVAC heater ventilation, air conditioning IPM integrated power module KNB knee blocker airbag LDU lower drive unit LHD left hand drive MIC mechanical instrument cluster MTC manual temperature control MSMAPM memory seat/mirror/adjustable pedals module NAV navigation NGC next generation controller OBD on board diagnostics OCM occupant classification module OCS occupant classification system OCSVR occupant classification system verification required ODO odometer ORC occupant restraint controller PAB passenger airbag PASS passenger PCI Programmable Communication Interface (vehicle communication bus) PCM powertrain control module PDC power distribution center PLG power liftgate Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4151 PLGM power liftgate module PSD power sliding door PSDM power sliding door module PWM pulse width modulated RHD Right Hand Drive RKE remote keyless entry RX receive SAB seat airbag SBS seat belt switch SBT seat belt tensioner SKREEM sentry key remote entry module SQUIB also called initiator (located inside airbag) SRS supplemental restraint system TCM transmission control module TPMS tire pressure monitor system TX transmit VFD vacuum fluorescent display VTSS vehicle theft security system Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4152 Body Control Module: Testing and Inspection Diagnostic Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes See: Testing and Inspection/Diagnostic Trouble Code Descriptions Diagnostic Trouble Code Tests and Associated Procedures For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures Air Bag System Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Any Station Preset Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4153 Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4154 POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Test 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4155 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Pause/Play Switch Inoperative Test 1 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4156 Test 1 SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Remote Radio Controls Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4157 Test 4 - 7 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4158 Test 8 - 9 SYMPTOM REMOTE RADIO CONTROLS INOPERATIVE POSSIBLE CAUSES - Open radio control MUX circuit at the switch - Open radio control MUX return circuit at the switch - Remote radio switch - Body control module - internal short - Open clockspring - Open radio control MUX circuit - Open radio control MUX return circuit - Body control module - open internal Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4159 Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4160 POSSIBLE CAUSES - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure ATC Head LED(s)/Backlighting Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4161 Test 1 - 3 Test 4 - 5 SYMPTOM ATC HEAD LED(S)/BACK LIGHTING INOPERATIVE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4162 POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - ATC - LED(s) inoperative - ATC - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4163 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4164 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4165 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4166 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4167 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM FUSE #10 - Fused front blower motor relay output circuit shorted to ground - Blower motor shorted to ground - Front blower power module shorted to ground - Ground circuit open - Blower motor control circuit shorted to voltage - Blower motor control circuit open - Front blower power module open - Automatic temperature control module open - Check blower motor operation - Front blower power module open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4168 Test 1 Test 2 SYMPTOM FRONT BLOWER RUNS AT ONLY ONE SPEED Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4169 POSSIBLE CAUSES - Blower motor control circuit shorted to ground - Automatic temperature control module - Front blower power module HVAC System Test Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4170 Test 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4171 Test 6 Test 7 SYMPTOM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4172 HVAC SYSTEM TEST POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active ATC DTC's - Check for AC cooldown test fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear ATC Switch LED(s)/Backlighting Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4173 Test 4 - 5 SYMPTOM REAR ATC SWITCH LED(S)/BACK LIGHTING INOPERATIVE POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - Rear ATC switch - LED(s) inoperative - Rear ATC switch - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4174 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4175 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4176 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4177 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4178 Test 15 - 16 SYMPTOM REAR BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM Fuse #12 - Fused rear blower relay output circuit shorted to ground - Blower motor shorted to ground - Rear blower motor power module shorted to ground - Ground circuit open - Rear blower motor control circuit shorted to voltage - Rear blower motor control circuit open - Rear blower motor power module open - Automatic temperature control module open - Check blower motor operation - Rear blower motor power module open - IPM - open circuit - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4179 Test 1 Test 2 SYMPTOM REAR BLOWER RUNS AT ONLY ONE SPEED POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4180 - Rear blower motor control circuit shorted to ground - Automatic temperature control module - Rear blower motor power module Chime Inoperative Test 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE POSSIBLE CAUSES - Use DRB to actuate chime - Chime driver circuit - open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4181 - Chime driver circuit - short to ground - Chime driver circuit - short to voltage - Instrument cluster - BCM Key In Ignition and Drivers Door Open Chime Not Operating Properly Test 1 - 3 SYMPTOM KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME NOT OPERATING PROPERLY POSSIBLE CAUSES - DRB chime actuator - Driver door ajar status - Ignition switch - Body control module Vehicle Speed Warning Chime Problem Test 1 SYMPTOM PROBLEM WITH THE VEHICLE SPEED WARNING CHIME POSSIBLE CAUSES - Incorrect country code programmed in BCM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4182 - Body control module Left Front Door Ajar Switch Sense Circuit Open Test 1 - 4 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Left front door ajar switch ground circuit open - Left front door (lock motor) ajar switch - Left front door ajar switch sense circuit open - Body control module internal malfunction Left Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4183 Test 1 - 2 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left front door (lock motor) ajar switch shorted to ground - Left front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Left Sliding Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4184 Test 1 - 3 Test 4 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Left sliding door ajar switch sense circuit open - Left sliding door ajar switch sense circuit open - Body control module internal malfunction Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4185 - Left sliding door lock motor/ajar switch (latch assy). Left Sliding Door Ajar Switch Sense Circuit Shorted to Ground Test 1 - 3 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left sliding door lock motor/ajar switch shorted to ground - Left sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Left sliding door lock motor/ajar switch (latch assy). Liftgate Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4186 Test 1 - 4 SYMPTOM LIFTGATE AJAR CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Liftgate ajar switch ground circuit open - Liftgate ajar switch (cinch/release motor) - Liftgate ajar switch sense circuit open - Body control module internal malfunction Liftgate Ajar Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4187 Test 1 - 2 SYMPTOM LIFTGATE AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Liftgate ajar switch shorted to ground - Liftgate ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4188 Test 1 - 4 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Right front door ajar switch ground circuit open - Right front door (lock motor) ajar switch - Right front door ajar switch sense circuit open - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4189 Test 1 - 2 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right front door (lock motor) ajar switch shorted to ground - Right front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Sliding Door Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4190 Test 1 - 3 Test 4 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Right sliding door ajar switch sense circuit open - Right sliding door ajar switch sense circuit open - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4191 Right Sliding Door Ajar Circuit Shorted to Ground Test 1 - 3 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right sliding door lock motor/ajar switch shorted to ground - Right sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) A/C Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4192 Test 1 - 2 Test 3 SYMPTOM A/C STATUS INDICATOR FLASHING - MTC POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Blend/Mode/Recirc Door Operation Improper -- Dual & Three-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4193 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4194 Test 4 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4195 Test 7 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4196 Test 10 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER -- DUAL & THREE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Passenger blend door actuator/linkage/door - Driver blend door actuator/linkage/door - Recirculation door actuator/linkage/door - Rear mode door actuator/linkage/door - Rear blend door actuator/linkage/door Blend/Mode/Recirc Door Operation Improper --Single-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4197 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4198 Test 4 - 7 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER --SINGLE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Blend door actuator/linkage/door - Recirculation door actuator/linkage/door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4199 Front A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Test 4 SYMPTOM FRONT A/C - HEATER CONTROL ILLUMINATION INOPERATIVE -MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - A/C - heater control module - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4200 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4201 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4202 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4203 Test 11 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4204 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #10 - Fused front blower motor relay output circuit shorted to ground - Front blower motor resistor block shorted to ground - Front blower motor resistor block shorted to ground - Blower motor - Blower motor - A/C - heater control module - Ground circuit open - Blower motor high driver circuit open - Front blower motor resistor block open - Front blower motor resistor block open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Motor Speeds Incorrect - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4205 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4206 Test 3 - 5 SYMPTOM FRONT BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Blower motor driver circuit(s) shorted to ground - Blower motor driver circuit(s) shorted to voltage - Blower motor driver circuits shorted together - A/C - heater control module - speeds incorrect - Blower motor driver circuit(s) open - Blower motor resistor block - open speed HVAC System Test - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4207 Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4208 Test 5 Test 5 SYMPTOM HVAC SYSTEM TEST - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4209 POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active HVAC DTC's and system tests fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4210 Test 4 - 5 SYMPTOM REAR A/C - HEATER CONTROL ILLUMINATION INOPERATIVE - MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - Inoperative bulb - Ground circuit open - Rear blower rear control switch - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4211 Test 1 - 2 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4212 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4213 Test 11 - 14 SYMPTOM REAR BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #12 - Fused rear blower motor relay output circuit shorted to ground - Blower motor - Ground circuit open - A/C - heater control module - Check for power to rear blower motor - Blower motor - Rear blower high speed circuit open - Rear blower motor high circuit open - Rear blower motor resistor block - IPM - open circuit Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4214 - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Motor Speeds Incorrect - MTC Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4215 Test 3 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4216 Test 6 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4217 Test 10 SYMPTOM REAR BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to ground - A/C - heater control module - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to voltage - Rear blower motor front control feed circuit shorted to voltage - Rear blower driver CKT(s) shorted to rear blower front control feed CKT - Rear blower motor driver circuits shorted together - A/C - heater control module - Rear blower motor driver circuit(s) open - Rear blower motor resistor block Rear Blower Rear Control Switch INOP In One or More Speeds - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4218 Test 1 - 2 Test 3 SYMPTOM REAR BLOWER REAR CONTROL SWITCH INOP IN ONE OR MORE SPEEDS - MTC POSSIBLE CAUSES - Rear blower motor driver circuit(s) open - Rear blower rear control switch - Rear blower motor front control feed circuit open - A/C - heater control module Recirc Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4219 Test 1 - 2 Test 3 SYMPTOM RECIRC STATUS INDICATOR FLASHING - MTC TEST NOTE This symptom is diagnosed using the test A/C STATUS INDICATOR FLASHING - MTC. POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Any PCI Bus Indicator Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4220 Test 1 - 4 SYMPTOM ANY PCI BUS INDICATOR INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - No response - instrument cluster - No response - ECM / PCM - Indicator inoperative - Instrument cluster Seat Belt Indicator Always On Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4221 Test 1 SYMPTOM SEAT BELT INDICATOR ALWAYS ON POSSIBLE CAUSES - ACM seat belt indicator command present - Instrument cluster Overhead Console Test 1 - 4 SYMPTOM REPAIRING CMTC DISPLAYS DOUBLE DASH (- - ) IN TEMP DISPLAY POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4222 - No response - PCI BUS - powertrain control module - CMTC BUS message failure - Compass mini-trip computer - Ambient temperature sensor - PCM ambient air temperature sensor DTC present - CMTC internal Left Cylinder Lock Switch Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4223 Test 4 - 5 SYMPTOM LEFT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - left cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - left cylinder lock switch MUX short to voltage Remote Keyless Entry Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4224 Test 1 - 4 Test 5 - 6 SYMPTOM REMOTE KEYLESS ENTRY INOPERATIVE POSSIBLE CAUSES - DTC present - SKREEM DTC present - Test transmitter with tester - RKE transmitter inoperative - RKE transmitter not programmed - SKREEM module - RKE inoperative - SKREEM module - RKE inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4225 Right Cylinder Lock Switch Inoperative Test 1 - 3 Test 4 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4226 SYMPTOM RIGHT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - right cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - right cylinder lock switch MUX short to voltage Power Doors - Liftgate Test 1 - 4 SYMPTOM POWER LIFTGATE INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Power Doors - Sliding Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4227 Test 1 - 4 SYMPTOM POWER SLIDING DOOR INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Alarm Trips On Its Own Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4228 Test 1 - 4 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - Last VTSS cause - Attempt to trip alarm - Intermittent condition Left Front Door Does Not Trip VTSS Test 1 SYMPTOM LEFT FRONT DOOR DOES NOT TRIP VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4229 POSSIBLE CAUSES - Body control module - Check DRBIII(R) for driver door ajar response Left Sliding Door Does Not Trip VTSS Test 1 SYMPTOM LEFT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Monitor DRBIII(R) for left sliding door ajar status - Body control module Right Front Door Does Not Trip VTSS Test 1 SYMPTOM RIGHT FRONT DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for passenger door ajar response - Body control module Right Sliding Door Does Not Trip VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4230 Test 1 SYMPTOM RIGHT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for right rear door ajar response - Body control module VTSS Will Not Arm Test 1 - 3 SYMPTOM VTSS WILL NOT ARM POSSIBLE CAUSES - Check the VTSS status - Check for BCM DTC's and VTSS arming inhibitors - Check for PCI BUS communication of instrument cluster and SKIM - Body control module Six Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4231 - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation Road Testing ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. WARNING: REASSEMBLE ALL COMPONENTS BEFORE ROAD TESTING A VEHICLE. DO NOT TRY TO READ THE DRBIII(R) SCREEN OR OTHER TEST EQUIPMENT DURING A TEST DRIVE. DO NOT HANG THE DRBIII(R) OR OTHER TEST EQUIPMENT FROM THE REARVIEW MIRROR DURING A TEST DRIVE. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIII(R) OR OTHER TEST EQUIPMENT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Vehicle Preparation For Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Glossary of Terms ABS antilock brake system ACT actuator APS adjustable pedals system ATC automatic temperature control BCM body control module BPS bladder pressure sensor BTS belt tension sensor CAB controller antilock brake CMTC compass/mini-trip computer CPA connector positive assurance DAB driver airbag DCHA diesel cabin heater assist (cabin heater) DLC data link connector DTC diagnostic trouble code DR driver EBL electric back lite (rear window defogger) ECM engine control module EVIC electronic vehicle information center FCM front control module GCC Gulf Coast Countries HE hall effect HFM hands free module HVAC heater ventilation, air conditioning IPM integrated power module KNB knee blocker airbag LDU lower drive unit LHD left hand drive MIC mechanical instrument cluster MTC manual temperature control MSMAPM memory seat/mirror/adjustable pedals module NAV navigation NGC next generation controller OBD on board diagnostics OCM occupant classification module OCS occupant classification system OCSVR occupant classification system verification required ODO odometer ORC occupant restraint controller PAB passenger airbag PASS passenger PCI Programmable Communication Interface (vehicle communication bus) PCM powertrain control module PDC power distribution center PLG power liftgate PLGM power liftgate module PSD power sliding door PSDM power sliding door module PWM pulse width modulated RHD Right Hand Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4232 RKE remote keyless entry RX receive SAB seat airbag SBS seat belt switch SBT seat belt tensioner SKREEM sentry key remote entry module SQUIB also called initiator (located inside airbag) SRS supplemental restraint system TCM transmission control module TPMS tire pressure monitor system TX transmit VFD vacuum fluorescent display VTSS vehicle theft security system DRB III Error Messages and Blank Screen DRBIII(R) ERROR MESSAGES Under normal operation, the DRBIII(R) will display one of only two error messages: user-requested WARM Boot or User-Requested COLD Boot. If the DRBIII(R) should display any other error message, record the entire display and call the STAR Center. This is a sample of such an error message display: ver:2.14 date: 26 Jul93 file: key_iff.cc date: Jul26 1993 line: 548 err: 0xi User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRBIII(R) DOES NOT POWER UP (BLANK SCREEN) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRBIII(R). Check for proper grounds at DLC cavities 4 and 5. If all connections are proper between the DRBIII(R) and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRBIII(R) may be the result or a faulty cable or vehicle wiring. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. DRB III Safety Information WARNING: EXCEEDING THE LIMITS OF THE DRBIII(R) MULTIMETER IS DANGEROUS. READ ALL DRBIII(R) INSTRUCTIONS BEFORE USING THE MULTIMETER. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4233 - Follow the vehicle manufacturer s service specifications at all times. - Do not use the DRBIII(R) if it has been damaged. - Do not use the test leads if the insulation is damaged or if metal is exposed. - To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. - Choose the proper range and functions for the measurement. Do not try voltage or current measurement that may exceed the rated capacity. - Do not exceed the limits shown in the table below: *Ohms cannot be measured if voltage is present. Ohms can be measured only in a non-powered circuit. - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10 A. - When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. - When measuring current, connect the meter in series with the load. - Disconnect the live test lead before disconnecting the common test lead. - When using the meter function, keep the DRBIII(R) away from spark plug or coil wires to avoid measuring error from outside interference. KDB Lab Scope Pattern Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 4234 PCI Bus Lab Scope Pattern Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 4235 Body Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lower instrument panel silencer. 3. Remove the knee blocker and reinforcement. 4. Disconnect the five wire connectors from the bottom of the Body Control Module (BCM). 5. Move bulkhead wiring aside. 6. Remove the screws holding the BCM to the bulkhead. 7. Remove the BCM from the mounting bracket. INSTALLATION 1. Install the BCM to the mounting bracket. 2. Install the screws holding the BCM to the bulkhead. 3. Connect the five wire connectors to the bottom of the Body Control Module (BCM). 4. Install the knee blocker and reinforcement. 5. Install the lower instrument panel silencer. 6. Connect the battery negative cable. 7. Verify proper operation of BCM and its functions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 4236 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRBIII(R) (diagnostic read-out box) Jumper wires Ohmmeter Voltmeter Sentry Key Tester Test Light 8443 SRS Airbag System Load Tool 9077 Occupant Classification Seat Weights Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs Engine Control Module: Technical Service Bulletins Engine Controls - Programming Generic PCMs NUMBER: 18-029-07 GROUP: Vehicle Performance DATE: April 26, 2007 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-006-04 REV. B, DATED SEPTEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A MINOR REVISION AND **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT UPDATED PL PARTS APPLICATIONS. SUBJECT: Generic Powertrain Control Module (PCM) Procedure OVERVIEW: This bulletin involves programming a generic PCM with software. MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR) Ram Truck 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004-2005 (KJ) Liberty 2004 - 2005 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2004-2005 (PL) Neon 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2005 (TJ) Wrangler Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 4241 NOTE: Refer to the table for specific applications. DISCUSSION: Mopar(R) is currently phasing out pre-programmed PCMs for the vehicles listed. New modules will no longer be pre-programmed when received from Mopar(R). Replacement of future PCMs will require programming utilizing the DRBIII(R) and TechCONNECT. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 4242 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 4243 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 4244 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 4245 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 4246 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: When flashing a 2002 - 2004 LH vehicle the BCM may need to be disconnected if experiencing failures during the flash of the transmission portion of the PCM. The BCM will need to be disconnected after the module ID portion of the flash is complete. Before pressing Page Forward to begin the flash of the PCM Turn the Key to the OFF position and disconnect the BCM. Then turn the KEY to the RUN position and Press Page Forward to begin the PCM flash session. NOTE: If vehicle is a DAKOTA, then the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for any erroneous DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRB III(R) reboots to the MAIN MENU, proceed to Step 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 4247 NOTE: If your vehicle is a 2002 LH and the original PCM part number begins with 04 the technician should use the 2002 LH Part Number Reference chart above to determine the corresponding "NEW" part number. This new number from the chart should then be entered into the Tech tools application as the original part number. If the original PCM number begins with 05 no change to the flash selection process is required. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the first ten (10) characters of the "PCM part # " on the repair order for later reference. NOTE: If the PCM is not operational, the part number can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step. 3. Page back to the "Main Menu" 4. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. 5. If the vehicle is not equipped with SKIM then proceed to step 6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with step 6. This information is available from one of the following: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. CAUTION: Failure to install the SKIM pin number into the module after flashing the PCM will cause a start and stall condition. 6. Replace the PCM using the appropriate generic control module. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E, Electronic Control Modules, Powertrain Control Module, Removal/Installation. 7. Open the hood, install a battery charger and verify battery state is above 11.5 volts. 8. If the old "PCM part # " is known, proceed to step 14. If the old "PCM part # " is not known, proceed to next step. 9. On DealerCONNECT select the "Service" tab. 10. Select "Vehicle Information Plus". 11. Manually enter the VIN and mileage and select "Enter". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 4248 12. Select the "Vehicle Option" tab. 13. Under the "Vehicle Option window, identify and record: a. Engine. b. Emissions (Federal or California). c. Transmission (Automatic, 5-speed manual, etc.). 14. Connect the DRBIII(R) to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 15. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates. NOTE: Do NOT enter the generic controller part number in step 16a below. 16. Determine the proper calibration: a. If the old "PCM part # " is known, enter the part number of the old controller in the "Parts Criteria p/n window. Proceed to step 16. b. If the old "PCM part # " is not known, select the correct calibration based on the information that was recorded from "Vehicle Options" in step 13. 17. Select the correct calibration. 18. Select the "Download/Update button. 19. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII(R). When the flash process is completed, proceed to next step. 20. Enter the VIN in the PCM. Using the DRBIII® select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "Engine" e. "Miscellaneous" f. "Check VIN" g. If the vehicle is not equipped with SKIM proceed to step 20h. If the vehicle is equipped with SKIM follow the directions on the DRBIII(R). When the VIN and SKIM key has been programmed, proceed to step 20. h. Enter the VIN as requested by the DRBIII(R). 21. Update the PCM mileage. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Check PCM Odometer" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 4249 g. "NO" h. Enter the current odometer mileage and then press "Enter". i. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter". 22. Proceed as follows: a. If the vehicle is equipped with an automatic transmission, proceed to step 24. b. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 24. c. If the vehicle is equipped with a Turbo engine and manual transmission, proceed to step 23. 23. On vehicles equipped with a Turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII® Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Pinion Factor" g. Select the correct tire size and then select "Page Back" to exit. h. Proceed to step 24. 24. On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Transmission" e. "Transmission Module" f. "Miscellaneous" g. "Pinion Factor" h. Select the correct tire size and then select "Page Back" to exit. i. Enter "Quick Learn" and then follow the instructions on the DRBIII(R). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 4250 25. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 4251 Engine Control Module: Technical Service Bulletins Engine Control - PCM Initialization Procedure NUMBER: 08-030-06 REV. A GROUP: Electrical DATE: August 25, 2006 THIS BULLETIN SUPERSEDES SERVICE BULLETINS 08-030-06, DATED JULY 12, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES REVISED CROSSFIRE AND SPRINTER INITIALIZATION PROCEDURES. SUBJECT: Powertrain Control Module Initialization MODELS: 2001-2004 (AN) Dakota 2004 - 2007 (CS) Pacifica 2007 (DC) Ram Cab & Chassis 2001 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2004 - 2007 (HB) Durango 2007 (HG) Aspen 1999 - 2000 (JA) Breeze/Cirrus/Stratus 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2007 (JS) Sebring 1998 - 2000 (JX) Sebring Convertible 2007 (KA) Nitro 2002 - 2007 (KJ) Liberty 1999 - 2004 (LH) 300M/Concorde/Intrepid/LHS 2005 - 2007 (LX) 300/Charger/Magnum 2007 (MK49) Compass 2007 (MK74) Patriot 2005-2007 (ND) Dakota 2000 - 2005 (PL) Neon/SX2.0 2007 (PM) Caliber 2001 - 2007 (PT) Chrysler PT Cruiser/Chrysler PT Cruiser Convertible 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 4252 1998 - 2006 (TJ) Wrangler 2004 - 2006 (VA) Sprinter 1999 -2004 (WJ) Grand Cherokee 2005 - 2007 (WK) Grand Cherokee 1999 - 2001 (XJ) Cherokee 2006 - 2007 (XK) Commander 2005 - 2006 (ZB) Viper 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster NOTE: The model years and vehicles above must be equipped (optional) with Sentry Key Theft Deterrent System (sales code GXX) for this bulletin to apply. DISCUSSION: ALL LISTED VEHICLES EXCEPT SEBRING COUPE/STRATUS COUPE (ST), CROSSFIRE, AND SPRINTER. When a Powertrain Control Module (PCM) is replaced on vehicles equipped with the Sentry Key(TM) Theft Deterrent System, it must be initialized to properly function with the anti-theft module. This is accomplished at a Chrysler Group Dealer by using the DRBIII(R) or StarSCAN(TM) Scan Tool to enter a PIN number. When the PIN number is not available from the vehicle owner or a Chrysler Group Scan Tool(s) is not available this can be accomplished by writing the Vehicle Identification Number (VIN) into the PCM using an after-market scan tool with a "VIN Write Function". More information is available from the scan tool manufacturer or the Equipment & Tool Institute. NOTE: After performing this procedure with an after-market scan tool on vehicles equipped with Chrysler Group's Next Generation Controller (NGC), Diagnostic Trouble Code (DTC) "P0633 - SKIM SECRET KEY DATA NOT STORED IN PCM" will be set. This DTC will not effect vehicle or system performance and cannot be erased. SEBRING COUPE/STRATUS COUPE (ST) Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), J1962 MMC Cable (Special Tool CH7010), and the BLUE 5T22 PCMCIA Diagnostic Card (Special Tool CH8425). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. CROSSFIRE AND SPRINTER. Initializing the PCM on these vehicles requires the use of a DaimlerChrysler scan tool (DRBIII(R)), Multiplexer cable box (Special Tool CH 9043), and the ORANGE Crossfire PCMCIA card (Special Tool CH9044) or the GREEN Sprinter PCMCIA card (Special Tool CH9087). This equipment is available for lease from DaimlerChrysler for short periods of time. A credit card deposit will be required. The DRBIII(R) will be shipped within 24 hours to your location by an overnight delivery service. When the DRBIII(R) is returned, your credit card will be charged the lease price. 2007 GRAND CHEROKEE W/ 3.0L TD/2005 - 2007 LIBERTY w/2.8L TD/2007 RAM TRUCK/RAM CAB CHASSIS w 6.7L TD AND 2004-2006 SPRINTER w 2.7L TD ENGINES. For the above models equipped with Turbo Diesel Engines, the fuel injector "Quantity Values" must be physically read from each injector and the values written to the ECU with an appropriate scan tool. **PCM INITIALIZATION PROCEDURE CROSSFIRE/SPRINTER**: NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 4253 Depending on the situation, there are two methods for initializing the PCM/ECM. Either Automatic Replacement or Service Replacement must be performed. Automatic Replacement uploads the data from the old controller and downloads data to the new controller when the part numbers are identical between the replacement and replaced controller. Service Replacement is used when part numbers are not identical or when the part number is not recognized by the DRBIII(R). Automatic Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" NOTE: For Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 7. "1. Module Auto Replacement" 8. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. Module Service Replacement 1. **Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 2. "1.1998 - 2007 Diagnostics" 3. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 4. "1. System Select" 5. "1. Engine" 6. "9. Miscellaneous Functions" 7. "7. Read PCM Coding for Crossfire" OR "6 Read ECM Coding for Sprinter" and record all data. NOTE: Record all information shown on the PCM/ECM screen for future use. Additionally, for Sprinter only, injector classification must be recorded. Under Miscellaneous Functions, select "5. Injector Classification" then "2. Injector Modification" on the DRBIII(R) and record the information for all 5 cylinders. 8. Install new controller using the procedures found in TechCONNECT. 9. Using the DRBIII(R), repeat above steps 1 through 6 and select "2. Module Service Replacement". 10. Follow the DRBIII(R) "On Screen" prompts until "Module Replacement Successful" message is displayed. 11. Was the message "Module Replacement Successful" received? a. Yes >> No Further Action is Required, Module has been successfully replaced. b. No >> proceed to the next Step # 12. 12. Open TechAUTHORITY. TechAUTHORITY is available on the internet. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Programming Generic PCMs > Page 4254 13. At the "Home" page, open the "Powertrain Control Module Initialization" link. 14. Open the "Coding String Calculator for Sprinter & Crossfire Vehicles" link. 15. Open the "Select Module" pull down menu and select "PCM". 16. Select the appropriate "Transmission Type" button (Manual or Automatic). 17. Carefully enter the 17 character VIN. 18. Carefully enter the PCM pin located on the new PCM. 19. Select the "Calculate" button at the bottom of the window. NOTE: TechAUTHORITY will automatically populate the "Coding String", "SCN", and "CheckSum" information. 20. Print the information from the technician's PC or accurately record the information. 21. Using the DRBIII(R) select: "1. DRBIII(R) Standalone" 22. "1.1998 - 2007 Diagnostics" 23. Make the appropriate selection: "5. 2004 - 2006 Crossfire" or "6. 2002 - 2006 Sprinter" 24. "1. System Select" 25. "1. Engine" 26. "9. Miscellaneous Functions" 27. "2. Module Service Replacement" 28. Follow the on screen instructions and carefully enter the "Coding String", "SCN" "CheckSum" and VIN information into the DRBIII(R)** NOTE: If one or more errors were made entering the data in step 28, the DRBIII(R) will display an error and ask that the data be checked and re-input as necessary. 29. Follow the DRBIII(R) "On Screen" prompts until 'Module Replacement Successful" message is displayed. PCM INITIALIZATION PROCEDURE SEBRING COUPE/STRAUS COUPE (ST): 1. Perform the "Registration Procedure" described in service bulletin 08-036-04. This service bulletin, including the password, is available on the internet under the "Powertrain Control Module Initialization" link. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4255 Engine Control Module: Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views Engine Control Module: Connector Views Powertrain Control Module C1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 4258 Powertrain Control Module C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 4259 Powertrain Control Module C3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Connector Views > Page 4260 Powertrain Control Module C4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 4261 Engine Control Module: Description and Operation Powertrain Control Module (PCM) The Powertrain Control Module (PCM) is a digital computer containing a microprocessor. The PCM receives input signals from various switches and sensors referred to as Powertrain Control Module Inputs. Based on these inputs, the PCM adjusts various engine and vehicle operations through devices referred to as Powertrain Control Module Outputs. NOTE: PCM Inputs: - Air Conditioning Pressure Transducer - Ambient temperature Sensor - ASD Relay - Battery Temperature Sensor (NGC) - Battery Voltage - Brake Switch - Camshaft Position Sensor - Crankshaft Position Sensor - Distance Sensor (from transmission control module) - EGR Position Feedback - Engine Coolant Temperature Sensor - Heated Oxygen Sensors - Ignition sense - Intake Air Temperature Sensor - Knock Sensor - Leak Detection Pump Feedback - Manifold Absolute Pressure (MAP) Sensor - Park/Neutral - PCI Bus - Power Steering Pressure Switch - Proportional Purge Sense - SCI Receive - Speed Control - Throttle Position Sensor - Transmission Control Relay (Switched B+) - Transmission Pressure Switches - Transmission Temperature Sensor - Transmission Input Shaft Speed Sensor - Transmission Output Shaft Speed Sensor - Transaxle Gear Engagement Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 4262 - Vehicle Speed NOTE: PCM Outputs: - Air Conditioning Clutch Relay - Automatic Shut Down (ASD) and Fuel Pump Relays - Data Link Connector (PCI and SCI Transmit) - Double Start Override - EGR Solenoid - Fuel Injectors - Generator Field - High Speed Fan Relay - Idle Air Control Motor - Ignition Coils - Leak Detection Pump - Low Speed Fan Relay - MTV Actuator - Proportional Purge Solenoid - SRV Valve - Speed Control Relay - Speed Control Vent Relay - Speed Control Vacuum Relay - 8 Volt Output - 5 Volt Output - Torque Reduction Request - Transmission Control Relay - Transmission Solenoids - Vehicle Speed Based on inputs it receives, the powertrain control module (PCM) adjusts fuel injector pulse width, idle speed, ignition timing, and canister purge operation. The PCM regulates the cooling fans, air conditioning and speed control systems. The PCM changes generator charge rate by adjusting the generator field. The PCM adjusts injector pulse width (air-fuel ratio) based on the following inputs. - Battery Voltage - Intake Air Temperature Sensor - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Exhaust Gas Oxygen Content (heated oxygen sensors) - Manifold Absolute Pressure - Throttle Position The PCM adjusts engine idle speed through the idle air control motor based on the following inputs. - Brake Switch - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Park/Neutral - Transaxle Gear Engagement - Throttle Position - Vehicle Speed The PCM adjusts ignition timing based on the following inputs. - Intake Air Temperature - Engine Coolant Temperature - Engine Speed (crankshaft position sensor) - Knock Sensor - Manifold Absolute Pressure - Park/Neutral - Transaxle Gear Engagement - Throttle Position The automatic shut down (ASD) and fuel pump relays are mounted externally, but turned on and off by the powertrain control module through the same circuit. The camshaft and crankshaft signals are sent to the powertrain control module. If the PCM does not receive both signals within approximately one second of engine cranking, it deactivates the ASD and fuel pump relays. When these relays are deactivated, power is shut off to the fuel injectors, ignition coils, fuel pump and the heating element in each oxygen sensor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 4263 The PCM contains a voltage converter that changes battery voltage to a regulated 8.0 volts. The 8.0 volts power the camshaft position sensor, crankshaft position sensor and vehicle speed sensor. The PCM also provides a 5.0 volts supply for the engine coolant temperature sensor, intake air temperature sensor, manifold absolute pressure sensor and throttle position sensor. The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage in new PCM. Use the DRBIII(R) scan tool to change the mileage in the PCM. TRANSMISSION CONTROL CLUTCH VOLUME INDEX (CVI) Example Of CVI Calculation An important function of the PCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The PCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the PCM that represents input shaft rpm. The Output Speed Sensor provides the PCM with output shaft speed information. By comparing the two inputs, the PCM can determine transaxle gear ratio. This is important to the CVI calculation because the PCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the PCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the PCM can determine the volume of fluid used to apply or release a friction element. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 4264 The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: SHIFT SCHEDULES As mentioned earlier, the PCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Part 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 4265 Part 2 As driving conditions change, the PCM appropriately adjusts the shift schedule. Refer to the chart to determine the appropriate operation expected, depending on driving conditions. SENSOR RETURN - PCM INPUT The sensor return circuit provides a low electrical noise ground reference for all of the systems sensors. The sensor return circuit connects to internal ground circuits within the Powertrain Control Module (PCM). DATA BUS COMMUNICATION RECEIVE - PCM INPUT The PCM uses the SCI communication bus to preform engine diagnostics and flash operations. The transmission side of the PCM uses the SCI communication bus to flash new software. However, diagnostics is performed via the vehicles J1850 bus for the transmission side of the PCM. IGNITION SENSE - PCM INPUT The ignition sense input informs the Powertrain Control Module (PCM) that the ignition switch is in the crank or run position. PCM GROUND Ground is provided through multiple pins of the PCM connector. Depending on the vehicle there may be as many as two different ground pins. There are power grounds and sensor grounds. The power grounds are used to control the ground side relays, solenoids, ignition coil or injectors. The signal ground is used for any input that uses sensor return for ground, and the ground side of any internal processing component. The PCM case is shielded to prevent RFI and EMI. The PCM case is grounded and must be firmly attached to a good, clean body ground. Internally all grounds are connected together, however there is noise suppression on the sensor ground. For EMI and RFI protection the housing and cover are also grounded separately from the ground pins. 5 VOLT SUPPLY - PCM OUTPUT The PCM supplies 5 volts to the following sensors: - A/C pressure transducer - Ambient Temperature sensor - Battery temperature - Camshaft Position Sensor (NGC) - Crankshaft Position Sensor (NGC) - Engine coolant temperature sensor - Inlet Air Temperature Sensor - Knock sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 4266 - Linear EGR solenoid (if equipped) - Manifold absolute pressure sensor - Oil Pressure Switch - Throttle position sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming Engine Control Module: Service and Repair PCM/SKIM Programming NOTE: Before replacing the PCM for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most PCM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. When a PCM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new PCM. 2. Program the new SKIM. 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE PCM The SKIS Secret Key is an ID code that is unique to each SKIM. This code is programmed and stored in the SKIM, PCM and transponder chip (ignition keys). When replacing the PCM it is necessary to program the secret key into the new PCM using the scan tool. Perform the following steps to program the secret key into the PCM. 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Enter secured access mode by entering the vehicle four-digit PIN. 5. Select ENTER to update PCM VIN. NOTE: If three attempts are made to enter secure access mode using an incorrect PIN, secured access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. (Ensure all accessories are turned off. Also monitor the battery state and connect a battery charger if necessary). 6. Press ENTER to transfer the secret key (the SKIM will send the secret key to the PCM). 7. Press Page Back to get to the Select System menu and select ENGINE, MISCELLANEOUS, and SRI MEMORY CHECK. 8. The scan tool will ask, Is odometer reading between XX and XX? Select the YES or NO button on the scan tool. If NO is selected, the scan tool will read, Enter odometer Reading. Enter the odometer reading from the Instrument Panel and press ENTER. PROGRAMMING THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PCM REPLACED (GAS ENGINE). 4. Program the vehicle four-digit PIN into SKIM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKIM, the SKIM must be replaced. 6. Select YES to update VIN (the SKIM will learn the VIN from the PCM). 7. Press ENTER to transfer the secret key (the PCM will send the secret key to the SKIM). 8. Program ignition keys to SKIM. NOTE: If the PCM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKIM 1. Turn the ignition switch on (transmission in park/neutral). 2. Use the scan tool and select THEFT ALARM, SKIM then MISCELLANEOUS. 3. Select PROGRAM IGNITION KEY'S. 4. Enter secured access mode by entering the vehicle four-digit PIN. NOTE: A maximum of eight keys can be learned to each SKIM. Once a key is learned to a SKIM it (the key) cannot be transferred to another vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following messages: Programming Not Attempted The scan tool attempts to read the programmed key status and there are no keys programmed into SKIM memory. Programming Key Failed (Possible Used Key From Wrong Vehicle) SKIM is unable to program key due to one of the following: - faulty ignition key transponder - ignition key is programmed to another vehicle. 8 Keys Already Learned, Programming Not Done Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming > Page 4269 - SKIM transponder ID memory is full. 5. Obtain ignition keys to be programmed from customer (8 keys maximum). 6. Using the scan tool, erase all ignition keys by selecting MISCELLANEOUS and ERASE ALL CURRENT IGN. KEYS. 7. Program all ignition keys. Learned Key In Ignition Ignition key transponder ID is currently programmed in SKIM memory. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming > Page 4270 Engine Control Module: Service and Repair Powertrain Control Module SBEC Controller REMOVAL 1. Disconnect the negative battery cable. 2. Remove the battery shield. PCM 3. Remove the 2 upper PCM bracket bolts. 4. Remove the 2 PCM connectors. 5. Remove the headlamp PCM Lower Bolt 6. Remove the lower PCM mounting bolt. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming > Page 4271 7. Remove PCM. INSTALLATION 1. Install the PCM. 2. Install the lower PCM mounting bolt. Tighten bolt. 3. Install the 2 upper PCM bracket bolts. Tighten bolt. 4. Install the headlamp. 5. Install the 2 PCM connectors. 6. Install the battery shield. 7. Connect the negative battery cable. NGC Controller REMOVAL NGC Controller Location The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage and vehicle identification number (VIN) in the new PCM. Use the DRBIII(R) scan tool to change the millage and VIN in the PCM. If this step is not done a Diagnostic Trouble Code (DTC) may be set. 1. Turn wheels to the left. 2. Disconnect the negative battery cable. 3. Raise vehicle and support. Splash Shield Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > PCM/SKIM Programming > Page 4272 4. Remove the left front wheel well splash shield. NGC Controller 5. Unlock and disconnect the electrical connectors. 6. Remove 3 screws from PCM to mounting bracket. 7. Remove the PCM. INSTALLATION The PCM engine control strategy prevents reduced idle speeds until after the engine operates for 320 km (200 miles). If the PCM is replaced after 320 km (200 miles) of usage, update the mileage and vehicle identification number (VIN) in the new PCM. Use the DRBIII(R) scan tool to change the millage and VIN in the PCM. If this step is not done a diagnostic trouble code (DTC) may be set and SKIM must be done or car will not start if it is a SKIM equipped car. If a SKIM car you must do a secret key transfer also. 1. Install PCM module to the mounting bracket. 2. Install electrical connectors and lock. 3. Install the splash shield. 4. Lower vehicle. 5. Connect the negative battery cable. 6. Using DRBIII(R) scan tool, program mileage and vehicle identification number (VIN) into PCM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4276 Main Relay (Computer/Fuel System): Diagrams Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4277 Auto Shut Down Relay Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4278 Main Relay (Computer/Fuel System): Description and Operation AUTO SHUT DOWN RELAY The relay is located in the Power Distribution Center (PDC). For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary The engine switched battery (NGC vehicles) informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is also used to power certain drivers on NGC vehicles. When energized, the ASD relay on NGC vehicles provides power to operate the injectors, ignition coil, generator field, O2 sensor heaters (both upstream and downstream), evaporative purge solenoid, EGR solenoid (if equipped) wastegate solenoid (if equipped), and NVLD solenoid (if equipped). The ASD relay also provides a sense circuit to the PCM for diagnostic purposes. If the PCM does not receive 12 volts from this input after grounding the control side of the ASD relay, it sets a Diagnostic Trouble Code (DTC). The PCM energizes the ASD any time there is an engine speed that exceeds a predetermined value (typically about 50 rpm). The ASD relay can also be energized after the engine has been turned off to perform an O2 sensor heater test, if vehicle is equipped with OBD II diagnostics. As mentioned earlier, the PCM energizes the ASD relay during an O2 sensor heater test. On NGC vehicles it checks the O2 heater upon vehicle start. The PCM still operates internally to perform several checks, including monitoring the O2 sensor heaters. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Specifications Specifications - Battery Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Specifications > Page 4283 Battery Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Specifications > Page 4284 Battery Temperature Sensor: Description and Operation (NGC Vehicles) The PCM incorporates a Battery Temperature Sensor (BTS) on its circuit board. The PCM uses the temperature of the battery area to control the charge system voltage. This temperature, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as temperature around the battery increases. For vehicles with 1.6L engine, there is no physical battery temp sensor in place to detect battery temp. Rather, an algorithm built in PCM is employed to predict battery temp using inlet air temp, vehicle speed, and coolant temp, among other signals. The PCM maintains the optimal output of the generator by monitoring battery voltage and controlling it to a range of 13.5 - 14.7 volts based on battery temperature. The system target voltage is 13.5 - 14.7 volts. However the actual voltage go below this during heavy electrical loads and generator speeds. Also the actual voltage can be lower than the target voltage between the battery and the battery voltage sense circuit, approximately 0.2 - 0.3 volts. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20°F. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Specifications > Page 4285 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor is not serviced separately. If replacement is necessary, the PCM must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 4290 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4291 Camshaft Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4292 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor EGR/CAM Sensor 2.4L The camshaft position sensor for the 3.3/3.8L is mounted in the front of the timing case cover and the camshaft position sensor for the 2.4L is mounted on the end of the cylinder head. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4293 Camshaft Position Sensor The camshaft position sensor provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it (Fig. 2). The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. Camshaft Position Sensor When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4294 Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the sensor. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs on represent which cylinder the flat spot and notches identify, they do not indicate TDC position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4295 NGC Typical Scope Patterns Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4296 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. Air Box Cover 2. Remove the air box cover and inlet tube. Camshaft Position Sensor 3. Disconnect camshaft position sensor electrical connector from the wiring harness connector. 4. Remove bolt holding sensor. 5. Rotate sensor away from block. 6. Pull sensor up out of the chain case cover. Do not pull on the sensor wiring. There is an O-ring on the body of the sensor. The O-ring may make removal difficult. A light tap to top of sensor prior to removal may reduce force needed for removal. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 4297 Camshaft Position Sensor And Spacer If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. While holding the sensor in this position, install and tighten the retaining bolt 14 N.m (125 in. lbs.) torque. 4. Connect camshaft position sensor electrical connector to harness connector. 5. Install the air box cover and inlet hose. 6. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations 3.3L & 3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 4305 Crankshaft Position Sensor: Connector Locations Starter Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 4306 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4307 Crankshaft Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4308 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR Crankshaft Sensor 2.4L The 2.4L crankshaft sensor is located on the rear of the engine near the accessory drive belt. The 3.3L/3.8L crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4309 Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 4310 NGC Typical Scope Patterns Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Pump Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4314 Fuel Level Sensor: Service and Repair Fuel Pump/Level Sensor Electrical Connector Wire Terminal Locking Finger Removing Wires From Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4315 Loosening Level Sensor Level Sensor Removal/Installation Groove In Back Side Of Level Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 4316 Installation Channel Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4321 Intake Air Temperature Sensor: Connector Locations Inlet Air Sensors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Component Locations > Page 4322 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4323 Inlet Air Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 4324 Intake Air Temperature Sensor: Description and Operation 3.3/3.8L IAT Sensor The IAT Sensor is a Negative Temperature Coefficient (NTC) Sensor that provides information to the PCM regarding the temperature of the air entering the intake manifold. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation The knock sensor threads into the cylinder block. The knock sensor is designed to detect engine vibration that is caused by detonation. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives as an input the knock sensor voltage signal. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except WOT. The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 4331 Manifold Absolute Pressure Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 4332 Manifold Pressure/Vacuum Sensor: Description and Operation Map Sensor 2.4L Map Sensor 3.3/3.8L The MAP sensor mounts to the intake manifold The sensor is connects electrically to the PCM The MAP serves as a PCM input, using a silicon based sensing unit, to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When MAP equals Barometric pressure, the pulse width will be at maximum. Also like the cam and crank sensors, a 5 volt reference is supplied from the PCM and returns a volt-age signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5 V and full scale is 4.5 V. For a pressure swing of 0 - 15 psi the voltage changes 4.O V. The sensor is supplied a regulated 4.8 to 5.1 volts to operate the sensor. Like the cam and crank sensors ground is provided through the sensor return circuit. The MAP sensor input is the number one contributor to pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or is it in Denver at 5000 feet above sea level, because the air density changes with altitude. It will also help to correct for varying weather conditions. If a hurricane was coming through the pressure would be very, very low or there could be a real fair weather, high pressure area. This is important because as air pressure changes the barometric pressure changes. Barometric pressure and altitude have a direct inverse correlation, as altitude goes up barometric goes down. The first thing that happens as the key is rolled on, before reaching the crank position, the PCM powers up, comes around and looks at the MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure relative to altitude. Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key on. The difference between current and what it was at key on is manifold vacuum. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 4333 During key On (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring known good sensor in you work area. As the altitude increases the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key On the barometric pressure needs to be updated. Any time the PCM sees Wide Open throttle, based upon TPS angle and RPM it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively The PCM uses the MAP sensor to aid in calculating the following: - Barometric pressure - Engine load - Manifold pressure - Injector pulse-width - Spark-advance programs - Shift-point strategies (F4AC 1 transmissions only via the PCI bus) - Idle speed - Decel fuel shutoff The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is 29.92 in Hg. For every 100 feet of altitude barometric pressure drops .10 in. Hg. If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude. You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 4334 Manifold Pressure/Vacuum Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. Map Sensor 3.3/3.8L 2. Remove vacuum hose and mounting screws from manifold absolute pressure (MAP) sensor. 3. Disconnect electrical connector from sensor. Remove sensor. INSTALLATION 1. Install sensor. 2. Install screws and tighten to PLASTIC MANIFOLD 1.7 N.m (15 in. lbs.) ALUMINUM MANIFOLD 3.3 N.m (30 in. lbs.). 3. Connect the electrical connector to the sensor. Install vacuum hose. 4. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Oxygen Sensors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 4338 3.3-3.8 Liter Engine Front Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 4339 Engine Pressure Switch (GAS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC P0135 Set NUMBER: 18-010-05 REV. A GROUP: Vehicle Performance DATE: March 4, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-010-05, DATED FEBRUARY 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN UPDATED VEHICLE BUILD DATE. THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD APRIL, 2005. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DIG) P0135 - 02 Sensor 1/1 Heater Performance OVERVIEW: This bulletin involves verifying the proper 1/1 02 Sensor is installed on the vehicle and reprogramming the Powertrain Control Module with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager NOTE: **This bulletin applies to 2005 CS and RS vehicles equipped with a 3.8L engine (sales code EGH) built on and between July 8, 2004 (MDH 0708XX) and March 2, 2005 (MDH 0302XX). 2005 RS vehicles equipped with a 3.3L engine (sales code EGA, EGM and EGH) built on and between July 8, 2004 (MDH 0708XX) and October 29, 2004 (MDH 1029XX).** SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by the following Diagnostic Trouble Codes (DTC's): P0135 - 02 Sensor 1/1 Heater Performance DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than the one listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. Verify that the correct 02 Sensor is installed on the vehicle. Refer to Service Bulletin 08-008-05. Installing an incorrect 1/1 02 sensor will cause a MIL illumination for DTC P0135 - 02 Sensor 1/1 Heater Performance to be set. If the vehicle operator describes or experiences the Symptom/Condition and the correct 1/1 02 sensor is installed on the vehicle, perform the Repair Procedure. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 4348 SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 4349 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Customer Interest for Oxygen Sensor: > 08-008-05 > Feb > 05 > Engine Controls - MIL ON/DTC P0135 (O2 Sensor) Oxygen Sensor: Customer Interest Engine Controls - MIL ON/DTC P0135 (O2 Sensor) NUMBER: 08-008-05 GROUP: Electrical DATE: February 4, 2005 SUBJECT: 1/1 02 Sensor Usage MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager 2005 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to 2005 CS vehicles equipped with a 3.8L engine (sales code EGH), 2005 RS or 2005 RG vehicles equipped with a 3.313.8L engine (sales code EGA, EGM and EGH). DISCUSSION: A new 1/1 02 sensor (PN 56029085AA) has been introduced on the 3.313.8L engines for the 2005 RS/RG and CS vehicles built after July 8, 2004 (MDH 0708XX). Installing an incorrect 1/1 02 sensor will cause a MIL illumination for DTC P0135 - 02 Sensor 1/1 Heater Performance to be set. The operation of the new 02 sensor has also changed. The new 1/1 02 sensor runs at 100% duty cycle all the time because the resistance of the heater is higher. Monitoring the 1/1 02 sensor with the DRBIII(R) while the vehicle is in the service bay will show 100% duty cycle, which is normal for this new sensor. 2005 Model Year 1/1 02 Sensor Usage POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0135 Set NUMBER: 18-010-05 REV. A GROUP: Vehicle Performance DATE: March 4, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-010-05, DATED FEBRUARY 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN UPDATED VEHICLE BUILD DATE. THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD APRIL, 2005. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DIG) P0135 - 02 Sensor 1/1 Heater Performance OVERVIEW: This bulletin involves verifying the proper 1/1 02 Sensor is installed on the vehicle and reprogramming the Powertrain Control Module with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager NOTE: **This bulletin applies to 2005 CS and RS vehicles equipped with a 3.8L engine (sales code EGH) built on and between July 8, 2004 (MDH 0708XX) and March 2, 2005 (MDH 0302XX). 2005 RS vehicles equipped with a 3.3L engine (sales code EGA, EGM and EGH) built on and between July 8, 2004 (MDH 0708XX) and October 29, 2004 (MDH 1029XX).** SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by the following Diagnostic Trouble Codes (DTC's): P0135 - 02 Sensor 1/1 Heater Performance DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than the one listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. Verify that the correct 02 Sensor is installed on the vehicle. Refer to Service Bulletin 08-008-05. Installing an incorrect 1/1 02 sensor will cause a MIL illumination for DTC P0135 - 02 Sensor 1/1 Heater Performance to be set. If the vehicle operator describes or experiences the Symptom/Condition and the correct 1/1 02 sensor is installed on the vehicle, perform the Repair Procedure. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 4359 SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 4360 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oxygen Sensor: > 08-008-05 > Feb > 05 > Engine Controls - MIL ON/DTC P0135 (O2 Sensor) Oxygen Sensor: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0135 (O2 Sensor) NUMBER: 08-008-05 GROUP: Electrical DATE: February 4, 2005 SUBJECT: 1/1 02 Sensor Usage MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager 2005 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to 2005 CS vehicles equipped with a 3.8L engine (sales code EGH), 2005 RS or 2005 RG vehicles equipped with a 3.313.8L engine (sales code EGA, EGM and EGH). DISCUSSION: A new 1/1 02 sensor (PN 56029085AA) has been introduced on the 3.313.8L engines for the 2005 RS/RG and CS vehicles built after July 8, 2004 (MDH 0708XX). Installing an incorrect 1/1 02 sensor will cause a MIL illumination for DTC P0135 - 02 Sensor 1/1 Heater Performance to be set. The operation of the new 02 sensor has also changed. The new 1/1 02 sensor runs at 100% duty cycle all the time because the resistance of the heater is higher. Monitoring the 1/1 02 sensor with the DRBIII(R) while the vehicle is in the service bay will show 100% duty cycle, which is normal for this new sensor. 2005 Model Year 1/1 02 Sensor Usage POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations Oxygen Sensor: Component Locations OBD-II Heated Oxygen Sensor Numbering Convention - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4367 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4368 Oxygen Sensor: Connector Locations Oxygen Sensors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4369 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page 4370 3.3-3.8 Liter Engine Front Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4371 Oxygen Sensor: Diagrams Oxygen Sensor 1/1 Upstream (3.3L/3.8L) Oxygen Sensor 1/2 Downstream (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4372 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4373 Oxygen Sensor: Description and Operation O2 Sensor Upstream 1/1 - 2.4L O2 Sensor Upstream 1/1 - 3.3/3.8L The upstream oxygen sensor threads into the outlet flange of the exhaust manifold. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4374 O2 Sensor Downstream 1/2 - 2.4/3.3/3.8L The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic convertor. A separate upstream and downstream grounds are used on the NGC vehicles (4 Cyl). As vehicles accumulate mileage, the catalytic convertor deteriorates. The deterioration results in a less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor, one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency. Also, the PCM uses the upstream heated oxygen sensor input when adjusting injector pulse width. When the catalytic converter efficiency drops below emission standards, the PCM stores a diagnostic trouble code and illuminates the malfunction indicator lamp (MIL). The 02 sensors produce a constant 2.5 volts on NGC vehicles, depending upon the oxygen content of the exhaust gas. When a large amount of oxygen is present (caused by a lean air/fuel mixture, can be caused by misfire and exhaust leaks), the sensors produces a low voltage. When there is a lesser amount of oxygen present (caused by a rich air/fuel mixture, can be caused by internal engine problems) it produces a higher voltage. By monitoring the oxygen content and converting it to electrical voltage, the sensors act as a rich-lean switch. The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop operation the PCM monitors the O2 sensors input (along with other inputs) and adjusts the injector pulse width accordingly. During Open Loop operation the PCM ignores the O2 sensor input. The PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. NGC Controller - Has a common ground for the heater in the 02S. 12 volts is supplied to the heater in the 02S by the NGC controller. Both the upstream and downstream 02 sensors for NGC are pulse width modulation (PWM). NOTE: When replacing an 02 Sensor, the PCM RAM memory must be cleared, either by disconnecting the PCM C-1 connector or momentarily disconnecting the Battery negative terminal. The NGC learns the characteristics of each O2 heater element and these old values should be cleared when installing a new 02 sensor. The customer may experience driveability issues if this is not performed. UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 2.5 to 3.5 volt, depending upon the oxygen content of the exhaust gas in the exhaust manifold. When a large amount of oxygen is present (caused by a lean air-fuel mixture), the sensor produces voltage as low as 2.5 volt. When there is a lesser amount of oxygen present (rich air/fuel mixture) the sensor produces a voltage as high as 3.5 volt. By monitoring the oxygen content and converting it to electrical voltage, the sensor acts as a rich-lean switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 4375 The heating element in the sensor provides heat to the sensor ceramic element. Heating the sensor allows the system to enter into closed loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle. In Closed Loop, the PCM adjusts injector pulse width based on the upstream heated oxygen sensor input along with other inputs. In Open Loop, the PCM adjusts injector pulse width based on preprogrammed (fixed) values and inputs from other sensors. DOWNSTREAM OXYGEN SENSOR The downstream heated oxygen sensor input is used to detect catalytic convertor deterioration. As the convertor deteriorates, the input from the downstream sensor begins to match the upstream sensor input except for a slight time delay. By comparing the downstream heated oxygen sensor input to the input from the upstream sensor, the PCM calculates catalytic convertor efficiency. Also used to establish the upstream 02 goal voltage (switching point). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor Oxygen Sensor: Service and Repair Downstream O2 Sensor REMOVAL - DOWNSTREAM 1/2 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Downstream Oxygen Sensor (1/2) 3. Disconnect the electrical connector. Downstream 2/1 O2 Sensor 4. Use a socket such as the Snap-On(R) YA8875 or equivalent to remove the sensor. 5. When the sensor is removed, the threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using the original sensor, coat the threads with Loctite 771 - 64 anti-seize compound or equivalent. INSTALLATION - DOWNSTREAM 2/1 The O2S is located on the side of the catalytic converter. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 4378 Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. 1. Install sensor and tighten to 27 N.m (20 ft. lbs.). 2. Connect the electrical connector. 3. Lower vehicle. 4. Install the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream O2 Sensor > Page 4379 Oxygen Sensor: Service and Repair Upstream Sensor REMOVAL - UPSTREAM 1/1 1. Remove battery, refer to the Battery section for more information. 2. Remove the battery tray, refer to the Battery section for more information. 3. Disconnect the speed control vacuum harness from servo. 4. Disconnect the electrical connector from servo. 5. Remove the speed control servo and bracket and reposition. O2 Sensor 1/1 6. Use a socket such as the Snap-On(R) YA8875 or equivalent to remove the sensor. 7. When the sensor is removed, the threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using the original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. INSTALLATION - UPSTREAM 1/1 The engines uses two heated oxygen sensors. 1. After removing the sensor, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If reusing the original sensor, coat the sensor threads with an anti-seize compound such as Loctite 771 - 64 or equivalent. New sensors have compound on the threads and do not require an additional coating. 2. Install sensor and tighten to 27 N.m (20 ft. lbs.). 3. Connect the electrical connector for the O2 sensor and install onto bracket. 4. Connect the electrical connector for the speed control servo. 5. Install the speed control servo and bracket refer to the Speed Control Servo for more information. 6. Connect the speed control vacuum harness to servo. 7. Install the battery tray, refer to the Battery section for more information. 8. Install battery, refer to the Battery section for more information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Page 4380 Oxygen Sensor: Tools and Equipment O2S (Oxygen Sensor) Removal/Install - C 4907 O2S (Oxygen Sensor) Removal/Install - 8439 O2S (Oxygen Sensor) Removal/Installation C 4907 O2S (Oxygen Sensor) Removal/Installer - 8439 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 4385 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4386 Throttle Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4387 Throttle Position Sensor: Description and Operation Throttle Position Sensor 2.4L Engine Throttle Position Sensor 3.3/3.8L Engine The throttle position sensor mounts to the side of the throttle body.The sensor connects to the throttle blade shaft. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4388 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the electrical connector from the Inlet Air Temperature sensor. 3. Remove the air cleaner box lid. Remove hose from throttle body. 4. Disconnect the electrical connector at TPS. 5. Disconnect the electrical connector at IAC. 6. Remove the throttle and speed control cables from throttle body. 7. Remove 3 mounting bolts from throttle body. 8. Remove throttle body. 9. Disconnect the purge vacuum line from the throttle body. 10. Remove TPS from throttle body. INSTALLATION 1. Install TPS to throttle body. 2. Disconnect the purge vacuum line from the throttle body. 3. Install throttle body. 4. Install 3 mounting bolts from throttle body. Tighten bolts. 5. Install the throttle and speed control cables to throttle body. 6. Connect the electrical connector at TPS. 7. Connect the electrical connector at IAC. 8. Install the air cleaner box lid. Install hose to throttle body. 9. Install the electrical connector to the Inlet Air Temperature sensor. 10. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR Sensor, Transmission Range Sensor ...................................................................................................................................................... 5 Nm (45 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 4394 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4395 Transmission Range Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 337). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 338). OPERATION The Transmission Range Sensor (TRS) (Fig. 337) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 4398 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 338) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 4399 Transmission Position Switch/Sensor: Description and Operation 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 303). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM/TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 304). OPERATION The Transmission Range Sensor (TRS) (Fig. 303) communicates Shift Lever Position (SLP) to the PCM/TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the PCM/TCM receives from four sense circuits. The PCM/TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the PCM/TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 4400 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 304) that the PCM/TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the PCM/TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the PCM/TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 4401 Transmission Position Switch/Sensor: Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle Transmission Position Switch/Sensor: Service and Repair 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 305). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 305) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 4404 Transmission Position Switch/Sensor: Service and Repair 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 339). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 339) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 4405 Transmission Position Switch/Sensor: Service and Repair 41TE REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 343). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 343) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation Vehicle Speed Sensor: Description and Operation Vehicle Speed and Distance Description The PCM receives a signal from the transaxle output speed sensor over the bus communication line. Operation The 4 speed automatic transaxle output speed sensor supplies the speed input to the PCM. The PCM determines acceleration rates. The speed control software in the PCM uses vehicle speed and acceleration to control to the set speed. For more information of the Output Speed Sensor please refer to: See: Transmission Control Systems/Sensors and Switches - Transmission and Drivetrain/Sensors and Switches A/T/Transmission Speed Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 4413 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4414 Throttle Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4415 Throttle Position Sensor: Description and Operation Throttle Position Sensor 2.4L Engine Throttle Position Sensor 3.3/3.8L Engine The throttle position sensor mounts to the side of the throttle body.The sensor connects to the throttle blade shaft. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4416 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the electrical connector from the Inlet Air Temperature sensor. 3. Remove the air cleaner box lid. Remove hose from throttle body. 4. Disconnect the electrical connector at TPS. 5. Disconnect the electrical connector at IAC. 6. Remove the throttle and speed control cables from throttle body. 7. Remove 3 mounting bolts from throttle body. 8. Remove throttle body. 9. Disconnect the purge vacuum line from the throttle body. 10. Remove TPS from throttle body. INSTALLATION 1. Install TPS to throttle body. 2. Disconnect the purge vacuum line from the throttle body. 3. Install throttle body. 4. Install 3 mounting bolts from throttle body. Tighten bolts. 5. Install the throttle and speed control cables to throttle body. 6. Connect the electrical connector at TPS. 7. Connect the electrical connector at IAC. 8. Install the air cleaner box lid. Install hose to throttle body. 9. Install the electrical connector to the Inlet Air Temperature sensor. 10. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR Sensor, Transmission Range Sensor ...................................................................................................................................................... 5 Nm (45 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 4422 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4423 Transmission Range Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 337). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 338). OPERATION The Transmission Range Sensor (TRS) (Fig. 337) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 4426 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 338) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 4427 Transmission Position Switch/Sensor: Description and Operation 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 303). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM/TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 304). OPERATION The Transmission Range Sensor (TRS) (Fig. 303) communicates Shift Lever Position (SLP) to the PCM/TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the PCM/TCM receives from four sense circuits. The PCM/TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the PCM/TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 4428 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 304) that the PCM/TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the PCM/TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the PCM/TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 4429 Transmission Position Switch/Sensor: Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle Transmission Position Switch/Sensor: Service and Repair 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 305). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 305) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 4432 Transmission Position Switch/Sensor: Service and Repair 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 339). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 339) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 4433 Transmission Position Switch/Sensor: Service and Repair 41TE REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 343). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 343) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation Vehicle Speed Sensor: Description and Operation Vehicle Speed and Distance Description The PCM receives a signal from the transaxle output speed sensor over the bus communication line. Operation The 4 speed automatic transaxle output speed sensor supplies the speed input to the PCM. The PCM determines acceleration rates. The speed control software in the PCM uses vehicle speed and acceleration to control to the set speed. For more information of the Output Speed Sensor please refer to: See: Transmission Control Systems/Sensors and Switches - Transmission and Drivetrain/Sensors and Switches A/T/Transmission Speed Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Component Locations Canister Purge Solenoid: Component Locations EVAP Purage Solenoid The solenoid attaches to a bracket near the radiator on the passenger side of vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Component Locations > Page 4443 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 4444 Canister Purge Solenoid: Description and Operation Proportional Purage Solenoid All vehicles use a proportional purge solenoid. The solenoid regulates the rate of vapor flow from the EVAP canister to the throttle body. The PCM operates the solenoid. During the cold start warm-up period and the hot start time delay, the PCM does not energize the solenoid. When de-energized, no vapors are purged. The proportional purge solenoid operates at a frequency of 200 hz and is controlled by an engine controller circuit that senses the current being applied to the proportional purge solenoid and then adjusts that current to achieve the desired purge flow. The proportional purge solenoid controls the purge rate of fuel vapors from the vapor canister and fuel tank to the engine intake manifold. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 4445 Canister Purge Solenoid: Service and Repair REMOVAL EVAP Purage Solenoid The solenoid attaches to a bracket near the radiator on the passenger side of vehicle.The solenoid will not operate unless it is installed correctly. 1. Disconnect electrical connector from solenoid. 2. Disconnect vacuum tubes from solenoid. 3. Remove solenoid from bracket. INSTALLATION The solenoid attaches to a bracket near the radiator on the passenger side of vehicle. The solenoid will not operate unless it is installed correctly. The top of the solenoid has TOP printed on it. The solenoid will not operate unless it is installed correctly. 1. Install solenoid on bracket. 2. Connect vacuum tube to solenoid. 3. Connect electrical connector to solenoid. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Check Valve: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4454 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4455 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Check Valve: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4461 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4462 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Evaporative Emission Control Canister: Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 4466 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 4467 Evaporative Emission Control Canister: Description and Operation Front EVAP Canister Rear EVAP Canister There are 2 EVAP canisters on the vehicle. The vacuum and vapor tubes connect to the top of the canister. It is a charcoal canister. All vehicles use a maintenance free, evaporative (EVAP) canister. Fuel tank vapors vent into the canister. The canister temporarily holds the fuel vapors until intake manifold vacuum draws them into the combustion chamber. The Powertrain Control Module (PCM) purges the canister through the proportional purge solenoid. The PCM purges the canister at predetermined intervals and engine conditions. Purge Free Cells Purge-free memory cells are used to identify the fuel vapor content of the evaporative canister. Since the evaporative canister is not purged 100% of the time, the PCM stores information about the evaporative canister s vapor content in a memory cell. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 4468 The purge-free cells are constructed similar to certain purge-normal cells. The purge-free cells can be monitored by the DRB III(R) Scan Tool. The only difference between the purge-free cells and normal adaptive cells is that in purge-free, the purge is completely turned off. This gives the PCM the ability to compare purge and purge-free operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Vapor Canister Evaporative Emission Control Canister: Service and Repair Vapor Canister REMOVAL 1. Raise and support the vehicle. Front EVAP Canister 2. Remove the 2 hoses. 3. Remove bolt. 4. Pull canister rearward to remove. INSTALLATION Front EVAP Canister Bracket 1. Install canister arrow heads into the rubber gromments. 2. Install bolt and tighten. 3. Install hoses. 4. Lower vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Vapor Canister > Page 4471 Evaporative Emission Control Canister: Service and Repair With NVLD-Fold-In-Floor REMOVAL 1. Raise and support the vehicle. 2. Remove the 3 hoses. Mounting Bolt 3. Remove bolt . 4. Pull canister rearward to remove. INSTALLATION Canister Mounting Studs 1. Install canister arrow heads into the rubber gromments. 2. Install bolt and tighten. 3. Install hoses. 4. Lower vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Vapor Canister > Page 4472 Evaporative Emission Control Canister: Service and Repair Rear EVAP Canister REMOVAL 1. Raise and support the vehicle. Rear Canister Location 2. Remove 3 hoses. 3. Remove the bolt. 4. Pull rearward to remove canister. INSTALLATION Rear EVAP Canister Bracket 1. Install canister arrow heads into the rubber gromments. 2. Install bolt and tighten. 3. Install hoses. 4. Lower vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Emissions Hose: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4481 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4482 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Emissions Hose: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4488 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4489 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Locations > Page 4493 Natural Vacuum Leak Detection Assembly (Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Natural VAC Leak Detection Assy Leak Detection Pump: Service and Repair Natural VAC Leak Detection Assy REMOVAL 1. Disconnect thew negative battery cable. NVLD Location 2. Raise vehicle and support. 3. Unlock and disconnect the electrical connector. 4. Remove the hoses from the NVLD valve. 5. Remove the 2 fasteners. NVLD Removal/Installation 6. Remove the valve and bracket from vehicle . Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Natural VAC Leak Detection Assy > Page 4496 NVLD Valve And Bracket 7. Remove valve from bracket. INSTALLATION 1. Install NVLD valve to the bracket . 2. Install valve and bracket to the vehicle. 3. Install the 2 mounting bolts and tighten. 4. Install the electrical connector and lock. 5. Install the 2 hoses and lock the clamps. 6. Lower vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Natural VAC Leak Detection Assy > Page 4497 Leak Detection Pump: Service and Repair Leak Detection Pump, Evaporative System REMOVAL 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. LDP Location 3. Remove 3 hoses. LDP Removal/Installation 4. Remove the electrical connector. 5. Remove the 3 screws and remove LDP pump. INSTALLATION 1. Install LDP. 2. Install the 3 screws and tighten. 3. Install the electrical connector. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detection Pump, Evaporative System > Component Information > Service and Repair > Natural VAC Leak Detection Assy > Page 4498 4. Install the 3 hoses. 5. Lower vehicle. 6. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation Refueling Vapor Recovery System: Description and Operation ORVR System Schematic The emission control principle used in the ORVR system is that the fuel flowing into the filler tube (appx. 1 I.D.) creates an aspiration effect which draws air into the fill tube. During refueling, the fuel tank is vented to the vapor canister to capture escaping vapors. With air flowing into the filler tube, there are no fuel vapors escaping to the atmosphere. Once the refueling vapors are captured by the canister, the vehicle s computer controlled purge system draws vapor out of the canister for the engine to burn. The vapors flow is metered by the purge solenoid so that there is no or minimal impact on driveability or tailpipe emissions. As fuel starts to flow through the fill tube, it opens the normally closed check valve and enters the fuel tank. Vapor or air is expelled from the tank through the control valve to the vapor canister. Vapor is absorbed in the canister until vapor flow in the lines stops, either following shut-off or by having the fuel level in the tank rise high enough to close the control valve. The control valve contains a float that rises to seal the large diameter vent path to the canister. At this point in the fueling of the vehicle, the tank pressure increases, the check valve closes (preventing tank fuel from spitting back at the operator), and fuel then rises up the filler tube to shut-off the dispensing nozzle. If the engine is shut-off while the On-Board diagnostics test is running, low level tank pressure can be trapped in the fuel tank and fuel can not be added to the tank until the pressure is relieved. This is due to the leak detection pump closing the vapor outlet from the top of the tank and the one-way check valve not allowing the tank to vent through the fill tube to atmosphere. Therefore, when fuel is added, it will back-up in the fill tube and shut off the dispensing nozzle. The pressure can be eliminated in two ways: 1. Vehicle purge must be activated and for a long enough period to eliminate the pressure. 2. Removing the fuel cap and allowing enough time for the system to vent thru the recirculation tube. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Component Locations > Page 4507 3.3-3.8 Liter Engine Front Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Locations > Page 4508 EGR Solenoid (3.8L Late Build/3.3L) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 4512 EGR Valve: Description and Operation MONITORED SYSTEMS There are new electronic circuit monitors that check fuel, emission, engine and ignition performance. These monitors use information from various sensor circuits to indicate the overall operation of the fuel, engine, ignition and emission systems and thus the emissions performance of the vehicle. The fuel, engine, ignition and emission systems monitors do not indicate a specific component problem. They do indicate that there is an implied problem within one of the systems and that a specific problem must be diagnosed. If any of these monitors detect a problem affecting vehicle emissions, the Malfunction Indicator (Check Engine) Lamp will be illuminated. These monitors generate Diagnostic Trouble Codes that can be displayed with the a scan tool. The following is a list of the system monitors: EGR Monitor (if equipped) Misfire Monitor Fuel System Monitor Oxygen Sensor Monitor Oxygen Sensor Heater Monitor Catalyst Monitor Evaporative System Leak Detection Monitor (if equipped) Following is a description of each system monitor, and its DTC. Refer to the appropriate Powertrain Diagnostics Procedures manual for diagnostic procedures. OXYGEN SENSOR (O2S) MONITOR Effective control of exhaust emissions is achieved by an oxygen feedback system. The most important element of the feedback system is the O2S. The O2S is located in the exhaust path. Once it reaches operating temperatures of 300° to 350°C (572° to 662°F), the sensor generates a voltage that is inversely proportional to the amount of oxygen in the exhaust. The information obtained by the sensor is used to calculate the fuel injector pulse width. The PCM is programmed to maintain the optimum air/fuel ratio. At this mixture ratio, the catalyst works best to remove hydrocarbons (HC), carbon monoxide (CO) and nitrous oxide (NOx) from the exhaust. The O2S is also the main sensing element for the EGR (if equipped), Catalyst and Fuel Monitors. The O2S may fail in any or all of the following manners: Slow response rate Reduced output voltage Dynamic shift Shorted or open circuits Response rate is the time required for the sensor to switch from lean to rich once it is exposed to a richer than optimum A/F mixture or vice versa. As the sensor starts malfunctioning, it could take longer to detect the changes in the oxygen content of the exhaust gas. The output voltage of the O2S ranges from 0 to 1 volt (voltages are offset by 2.5 volts on NGC vehicles). A good sensor can easily generate any output voltage in this range as it is exposed to different concentrations of oxygen. To detect a shift in the A/F mixture (lean or rich), the output voltage has to change beyond a threshold value. A malfunctioning sensor could have difficulty changing beyond the threshold value. OXYGEN SENSOR HEATER MONITOR If there is an oxygen sensor (O2S) DTC as well as a O2S heater DTC, the O2S heater fault MUST be repaired first. After the O2S fault is repaired, verify that the heater circuit is operating correctly. Effective control of exhaust emissions is achieved by an oxygen feedback system. The most important element of the feedback system is the O2S. The O2S is located in the exhaust path. Once it reaches operating temperatures of 300° to 350°C (572 ° to 662°F), the sensor generates a voltage that is inversely proportional to the amount of oxygen in the exhaust. The information obtained by the sensor is used to calculate the fuel injector pulse width. This maintains a 14.7 to 1 Air Fuel (A/F) ratio. At this mixture ratio, the catalyst works best to remove hydrocarbons (HC), carbon monoxide (CO) and nitrogen oxide (NOx) from the exhaust. The voltage readings taken from the O2S are very temperature sensitive. The readings are not accurate below 300°C (572 °F) Heating of the O2S is done to allow the engine controller to shift to closed loop control as soon as possible. The heating element used to heat the O2S must be tested to ensure that it is heating the sensor properly. The O2S circuit is monitored for a drop in voltage. The sensor output is used to test the heater by isolating the effect of the heater element on the O2S Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 4513 output voltage from the other effects. EGR MONITOR (if equipped) The Powertrain Control Module (PCM) performs an on-board diagnostic check of the EGR system. The EGR monitor is used to test whether the EGR system is operating within specifications. The diagnostic check activates only during selected engine/driving conditions. When the conditions are met, the EGR is turned off (solenoid energized) and the O2S compensation control is monitored. Turning off the EGR shifts the air fuel (A/F) ratio in the lean direction. The O2S data should indicate an increase in the O2 concentration in the combustion chamber when the exhaust gases are no longer recirculated. While this test does not directly measure the operation of the EGR system, it can be inferred from the shift in the O2S data whether the EGR system is operating correctly. Because the O2S is being used, the O2S test must pass its test before the EGR test. Also looks at EGR linear potentiometer for feedback. MISFIRE MONITOR Excessive engine misfire results in increased catalyst temperature and causes an increase in HC emissions. Severe misfires could cause catalyst damage. To prevent catalytic convertor damage, the PCM monitors engine misfire. The Powertrain Control Module (PCM) monitors for misfire during most engine operating conditions (positive torque) by looking at changes in the crankshaft speed. If a misfire occurs the speed of the crankshaft will vary more than normal. FUEL SYSTEM MONITOR To comply with clean air regulations, vehicles are equipped with catalytic converters. These converters reduce the emission of hydrocarbons, oxides of nitrogen and carbon monoxide. The catalyst works best when the air fuel (A/F) ratio is at or near the optimum of 14.7 to 1. The PCM is programmed to maintain the optimum air/fuel ratio. This is done by making short term corrections in the fuel injector pulse width based on the O2S output. The programmed memory acts as a self calibration tool that the engine controller uses to compensate for variations in engine specifications, sensor tolerances and engine fatigue over the life span of the engine. By monitoring the actual air-fuel ratio with the O2S (short term) and multiplying that with the program long-term (adaptive) memory and comparing that to the limit, it can be determined whether it will pass an emissions test. If a malfunction occurs such that the PCM cannot maintain the optimum A/F ratio, then the MIL will be illuminated. CATALYST MONITOR To comply with clean air regulations, vehicles are equipped with catalytic converters. These converters reduce the emission of hydrocarbons, oxides of nitrogen and carbon monoxide. Normal vehicle miles or engine misfire can cause a catalyst to decay. A meltdown of the ceramic core can cause a reduction of the exhaust passage. This can increase vehicle emissions and deteriorate engine performance, driveability and fuel economy. The catalyst monitor uses dual oxygen sensors (O2S's) to monitor the efficiency of the converter. The dual O2S's strategy is based on the fact that as a catalyst deteriorates, its oxygen storage capacity and its efficiency are both reduced. By monitoring the oxygen storage capacity of a catalyst, its efficiency can be indirectly calculated. The upstream O2S is used to detect the amount of oxygen in the exhaust gas before the gas enters the catalytic converter. The PCM calculates the A/F mixture from the output of the O2S. A low voltage indicates high oxygen content (lean mixture). A high voltage indicates a low content of oxygen (rich mixture). When the upstream O2S detects a lean condition, there is an abundance of oxygen in the exhaust gas. A functioning converter would store this oxygen so it can use it for the oxidation of HC and CO. As the converter absorbs the oxygen, there will be a lack of oxygen downstream of the converter. The output of the downstream O2S will indicate limited activity in this condition. As the converter loses the ability to store oxygen, the condition can be detected from the behavior of the downstream O2S. When the efficiency drops, no chemical reaction takes place. This means the concentration of oxygen will be the same downstream as upstream. The output voltage of the downstream O2S copies the voltage of the upstream sensor. The only difference is a time lag (seen by the PCM) between the switching of the O2S's. To monitor the system, the number of lean-to-rich switches of upstream and downstream O2S's is counted. The ratio of downstream switches to upstream switches is used to determine whether the catalyst is operating properly. An effective catalyst will have fewer downstream switches than it has upstream switches i.e., a ratio closer to zero. For a totally ineffective catalyst, this ratio will be one-to-one, indicating that no oxidation occurs in the device. The system must be monitored so that when catalyst efficiency deteriorates and exhaust emissions increase to over the legal limit, the MIL (Check Engine lamp) will be illuminated. NATURAL VACUUM LEAK DETECTION (NVLD) (if equipped) The Natural Vacuum Leak Detection (NVLD) system is the next generation evaporative leak detection system that will first be used on vehicles equipped with the Next Generation Controller (NGC). This new system replaces the leak detection pump as the method of evaporative system leak Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 4514 detection. This is to detect a leak equivalent to a 0.020" (0.5 mm) hole. This system has the capability to detect holes of this size very dependably. The basic leak detection theory employed with NVLD is the "Gas Law". This is to say that the pressure in a sealed vessel will change if the temperature of the gas in the vessel changes. The vessel will only see this effect if it is indeed sealed. Even small leaks will allow the pressure in the vessel to come to equilibrium with the ambient pressure. In addition to the detection of very small leaks, this system has the capability of detecting medium as well as large evaporative system leaks. The NVLD seals the canister vent during engine off conditions. If the EVAP system has a leak of less than the failure threshold, the evaporative system will be pulled into a vacuum, either due to the cool down from operating temperature or diurnal ambient temperature cycling. The diurnal effect is considered one of the primary contributors to the leak determination by this diagnostic. When the vacuum in the system exceeds about 1" H2O (0.25 KPA), a vacuum switch closes. The switch closure sends a signal to the NGC. The NGC, via appropriate logic strategies (described below), utilizes the switch signal, or lack thereof, to make a determination of whether a leak is present. The NVLD device is designed with a normally open vacuum switch, a normally closed solenoid, and a seal, which is actuated by both the solenoid and a diaphragm. The NVLD is located on the atmospheric vent side of the canister. The NVLD assembly may be mounted on top of the canister outlet, or in-line between the canister and atmospheric vent filter. The normally open vacuum switch will close with about 1" H2O (0.25 KPA) vacuum in the evaporative system. The diaphragm actuates the switch. This is above the opening point of the fuel inlet check valve in the fill tube so cap off leaks can be detected. Submerged fill systems must have recirculation lines that do not have the in-line normally closed check valve that protects the system from failed nozzle liquid ingestion, in order to detect cap off conditions. The normally closed valve in the NVLD is intended to maintain the seal on the evaporative system during the engine off condition. If vacuum in the evaporative system exceeds 3" to 6" H2O (0.75 to 1.5 KPA), the valve will be pulled off the seat, opening the seal. This will protect the system from excessive vacuum as well as allowing sufficient purge flow in the event that the solenoid was to become inoperative. The solenoid actuates the valve to unseal the canister vent while the engine is running. It also will be used to close the vent during the medium and large leak tests and during the purge flow check. This solenoid requires initial 1.5 amps of current to pull the valve open but after 100 ms. will be duty cycled down to an average of about 150 mA for the remainder of the drive cycle. Another feature in the device is a diaphragm that will open the seal in the NVLD with pressure in the evaporative system. The device will "blow off" at about 0.5" H2O (0.12 KPA) pressure to permit the venting of vapors during refueling. An added benefit to this is that it will also allow the tank to "breathe" during increasing temperatures, thus limiting the pressure in the tank to this low level. This is beneficial because the induced vacuum during a subsequent declining temperature will achieve the switch closed (pass threshold) sooner than if the tank had to decay from a built up pressure. The device itself has 3 wires: Switch sense, solenoid driver and ground. The NGC utilizes a high-side driver to energize and duty-cycle the solenoid. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 4515 EGR Valve: Service and Repair REMOVAL - 3.3L/3.8L 1. Disconnect and isolate negative battery cable. 2. Remove accessory drive belt. 3. Remove generator mounting bolts and reposition generator. 4. Unlock and disconnect the electrical connector from the EGR valve. 5. Remove the 2 EGR tube bolts. 6. Remove the 2 mounting bolts for the EGR valve and gasket. INSTALLATION - 3.3L/3.8L 1. Install a new gasket on the EGR valve. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 4516 2. Position EGR valve to cylinder head and install the 2 mounting bolts. 3. Tighten EGR valve mounting bolts to 31 Nm (23 ft.lbs). 4. Position EGR tube to EGR valve and install the 2 mounting bolts. 5. Tighten EGR tube mounting bolts to 13 Nm (115 in.lbs). 6. Connect electrical connector to EGR valve. 7. Install generator mounting bolts. 8. Install accessory drive belt. 9. Connect negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > Customer Interest for PCV Valve Hose: > 09-003-05 > Jun > 05 > Engine Compartment - Squeak Under Light Throttle PCV Valve Hose: Customer Interest Engine Compartment - Squeak Under Light Throttle NUMBER: 09-003-05 GROUP: Engine DATE: June 23, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL JULY 5, 2005. SUBJECT: Engine Compartment Squeak Under Light Throttle Tip-in OVERVIEW: This bulletin involves replacing the PCV hose to prevent interference with the bottom of the wiper module. MODELS: 2005 (RG) Chrysler Voyager (International Markets) 2005 (RS) Town & Country/Caravan/Voyager NOTE: This bulletin applies to 2005 RS or RG vehicles equipped with a 3.3/3.8L engine (sales code EGA, EGH and EGM): ^ built at St. Louis assembly between November 10, 2004 (MDH 1110XX) and May 13, 2005 (MDH 05113X) ^ built at Windsor assembly between November 7, 2004 (MDH 1107XX) and May 11, 2005 (MDH 0511XX) ^ built at Graz assembly between November 20, 2004 (MDH 1120XX) and May 27, 2005 (MDH 0527XX) SYMPTOM/CONDITION: A squeak sound heard after light throttle tip-in. The squeak is not heard at idle or under heavy load. DIAGNOSIS: Open hood and inspect the PCV hose for signs of contact with the bottom of the wiper module. If the PCV hose is contacting the bottom of the wiper module proceed to the repair procedure. It may be necessary to start the vehicle and apply a light throttle tip-in while looking to see if the hose is contacting the bottom of the wiper module. If the PCV hose is not contacting the bottom of the wiper module this bulletin does not apply and further diagnosis is required to determine the cause of the squeaking sound. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the PCV hose. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > Customer Interest for PCV Valve Hose: > 09-003-05 > Jun > 05 > Engine Compartment - Squeak Under Light Throttle > Page 4526 2. Replace the PCV hose with p/n 04781252AE. Be sure to orientate the PCV hose clamp correctly on the valve cover (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PCV Valve Hose: > 09-003-05 > Jun > 05 > Engine Compartment - Squeak Under Light Throttle PCV Valve Hose: All Technical Service Bulletins Engine Compartment - Squeak Under Light Throttle NUMBER: 09-003-05 GROUP: Engine DATE: June 23, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL JULY 5, 2005. SUBJECT: Engine Compartment Squeak Under Light Throttle Tip-in OVERVIEW: This bulletin involves replacing the PCV hose to prevent interference with the bottom of the wiper module. MODELS: 2005 (RG) Chrysler Voyager (International Markets) 2005 (RS) Town & Country/Caravan/Voyager NOTE: This bulletin applies to 2005 RS or RG vehicles equipped with a 3.3/3.8L engine (sales code EGA, EGH and EGM): ^ built at St. Louis assembly between November 10, 2004 (MDH 1110XX) and May 13, 2005 (MDH 05113X) ^ built at Windsor assembly between November 7, 2004 (MDH 1107XX) and May 11, 2005 (MDH 0511XX) ^ built at Graz assembly between November 20, 2004 (MDH 1120XX) and May 27, 2005 (MDH 0527XX) SYMPTOM/CONDITION: A squeak sound heard after light throttle tip-in. The squeak is not heard at idle or under heavy load. DIAGNOSIS: Open hood and inspect the PCV hose for signs of contact with the bottom of the wiper module. If the PCV hose is contacting the bottom of the wiper module proceed to the repair procedure. It may be necessary to start the vehicle and apply a light throttle tip-in while looking to see if the hose is contacting the bottom of the wiper module. If the PCV hose is not contacting the bottom of the wiper module this bulletin does not apply and further diagnosis is required to determine the cause of the squeaking sound. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the PCV hose. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > PCV Valve Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PCV Valve Hose: > 09-003-05 > Jun > 05 > Engine Compartment - Squeak Under Light Throttle > Page 4532 2. Replace the PCV hose with p/n 04781252AE. Be sure to orientate the PCV hose clamp correctly on the valve cover (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Specifications Torque Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Specifications > Page 4536 Positive Crankcase Ventilation Valve: Locations PCV Valve 2.4L PCV Valve 3.3/3.8L The PCV valve contains a spring loaded plunger. The plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Specifications > Page 4537 Engine Off Or Engine Backfire No Vapor Flow When the engine is not operating or during an engine backfire, the spring forces the plunger back against the seat. This prevents vapors from flowing through the valve. High In Take Manifold Vacuum Minimal Vapor Flow When the engine is at idle or cruising, high manifold vacuum is present. At these times manifold vacuum is able to completely compress the spring and pull the plunger to the top of the valve. In this position there is minimal vapor flow through the valve. Moderate In Take Manifold Vacuum Maximum Vapor Flow During periods of moderate intake manifold vacuum the plunger is only pulled part way back from the inlet. This results in maximum vapor flow through the valve. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Specifications > Page 4538 Positive Crankcase Ventilation Valve: Description and Operation PCV Valve 2.4L PCV Valve 3.3/3.8L The PCV valve contains a spring loaded plunger. The plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Specifications > Page 4539 Engine Off Or Engine Backfire No Vapor Flow When the engine is not operating or during an engine backfire, the spring forces the plunger back against the seat. This prevents vapors from flowing through the valve. High In Take Manifold Vacuum Minimal Vapor Flow When the engine is at idle or cruising, high manifold vacuum is present. At these times manifold vacuum is able to completely compress the spring and pull the plunger to the top of the valve. In this position there is minimal vapor flow through the valve. Moderate In Take Manifold Vacuum Maximum Vapor Flow During periods of moderate intake manifold vacuum the plunger is only pulled part way back from the inlet. This results in maximum vapor flow through the valve. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ............................... 400 kPa ± 34 kPa (58 psi ± 5 psi) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check Fuel Pressure: Testing and Inspection Fuel Delivery Check Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 4546 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 4547 Test 7 - 9 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specs - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump module - Fuel delivery system operation - Fuel pump relay fused B+ circuit - (A141) fuel pump relay output circuit open - (Z1) fuel pump ground circuit open/high resistance - Fuel pump module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 4548 Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test Test 1 - 2 SYMPTOM CHECKING FUEL PRESSURE LEAK DOWN POSSIBLE CAUSES - Checking fuel pressure - Fuel pump module - Checking fuel leak down Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair Accelerator Pedal: Service and Repair REMOVAL Throttle Cable Release 1. Hold the throttle body throttle lever in the wide open position. Remove the throttle cable from the throttle body cam. Throttle Cable Release 2. From inside the vehicle, hold up the pedal and remove the pedal retainer and throttle cable from the upper end of the pedal lever. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Page 4552 Accelerator Pedal And Throttle Cable 3. Remove nuts from accelerator pedal attaching studs. Remove assembly from vehicle. INSTALLATION 1. Position accelerator pedal assembly on dash panel. Install retaining nuts. Tighten retaining nuts to 12 N.m (105 in. lbs.) torque. 2. From inside the vehicle, hold up the pedal and install the throttle cable and pedal retainer in the upper end of the pedal lever. 3. From the engine compartment, hold the throttle body lever in the wide open position and install the throttle cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Specifications Fuel: Specifications Fuel Type ............................................................................................................................................. ................................................................. 87 Octane Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation Fuel Filler Cap: Description and Operation The plastic fuel fill cap is threaded/quarter turn onto the end of the fuel filler tube. It s purpose is to retain vapors and fuel in the fuel tank. The fuel filler cap incorporates a two-way relief valve that is closed to atmosphere during normal operating conditions. The relief valve is calibrated to open when a pressure of 17 kPa (2.5 psi) or vacuum of 2 kPa (0.6 in. Hg) occurs in the fuel tank. When the pressure or vacuum is relieved, the valve returns to the normally closed position. CAUTION: Remove the fuel filler cap to release fuel tank pressure before disconnecting any fuel system component. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Page 4562 Fuel Injector: Diagrams Fuel Injector No.1 (2.4L/3.3L/3.8L) Fuel Injector No.2 (2.4L/3.3L/3.8L) Fuel Injector No.3 (2.4L/3.3L/3.8L) Fuel Injector No.4 (2.4L/3.3L/3.8L) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Page 4563 Fuel Injector No.5 (3.3L/3.8L) Fuel Injector No.6 (3.3L/3.8L) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Page 4564 Fuel Injector: Description and Operation Fuel Injector Location - Typical The injectors are positioned in the intake manifold or cylinder head with the nozzle ends directly above the intake valve port. Fuel Injector Typical The fuel injectors are 12 volt electrical solenoids. The injector contains a pintle that closes off an orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a hollow cone or two streams. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber. Fuel injectors are not interchangeable between engines. The PCM provides battery voltage to each injector through the ASD relay. Injector operation is controlled by a ground path provided for each injector by the PCM. Injector on-time (pulse-width) is variable, and is determined by the PCM processing all the data previously discussed to obtain the optimum injector pulse width for each operating condition. The pulse width is controlled by the duration of the ground path provided. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Page 4565 Fuel Injector: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the Intake Manifold. 3. Disconnect injector wiring connector from injector. Fuel Injector And Rail Typical 4. Position fuel rail assembly so that the fuel injectors are easily accessible. 5. Rotate injector and pull injector out of fuel rail. The clip will stay on the injector. 6. Check injector O-ring for damage. If O-ring is damaged, it must be replaced. If injector is reused, a protective cap must be installed on the injector tip to prevent damage. Replace the injector clip if it is damaged. 7. Repeat for remaining injectors. INSTALLATION 1. Before installing an injector the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation. 2. Install injector clip by sliding open end into the top slot of the injector. The edge of the receiver cup will slide into the side slots of clip. 3. Install injector top end into fuel rail receiver cap. Be careful not to damage O-ring during installation. 4. Repeat steps for remaining injectors. 5. Install fuel rail, refer to Fuel Rail in the Fuel Delivery section. 6. Connect fuel injector wiring. 7. Install the Intake Manifold. 8. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions Fuel Line Coupler: Service Precautions Some components of the powertrain system are intended to be serviced in assembly only. Attempting to remove or repair certain system sub-components may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures should be serviced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Page 4569 Fuel Line Coupler: Service and Repair STANDARD PROCEDURE - QUICK-CONNECT FITTINGS REMOVAL When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple. WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE DISCONNECTING A QUICK-CONNECT FITTINGS. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE.THIS MAY RESULT IN PERSONAL INJURY OR DEATH. 1. Perform Fuel Pressure Release Procedure. Refer to the Fuel Pressure Release Procedure. 2. Disconnect negative cable from battery or auxiliary jumper terminal. 3. Squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off of fuel tube nipple. The retainer will remain on fuel tube. INSTALLATION CAUTION: Make sure that the O-ring in installed in fitting Never install a quick-connect fitting without the retainer being either on the fuel tube or already in the quick-connect fitting. In either case, ensure the retainer locks securely into the quick-connect fitting by firmly pulling on fuel tube and fitting to ensure it is secured. 1. Using a clean lint free cloth, clean the fuel tube nipple and retainer. 2. Prior to connecting the fitting to the fuel tube, coat the fuel tube nipple with clean engine oil. 3. Push the quick-connect fitting over the fuel tube until the retainer seats and a click is heard. Plastic Quick Connect Fitting/Fuel Tube Connection 4. The plastic quick-connect fitting has windows in the sides of the casing. When the fitting completely attaches to the fuel tube, the retainer locking ears and the fuel tube shoulder are visible in the windows. If they are not visible, the retainer was not properly installed. Do not rely upon the audible click to confirm a secure connection. 5. Connect negative cable to battery or auxiliary jumper terminal. CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for several minutes, until the test is stopped, or until the ignition switch is turned to the Off position. 6. Use the DRBIII(R) scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. TWO-TAB TYPE FITTING Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Page 4570 Typical Two Tab Quick Connect Fitting This type of fitting is equipped with tabs located on both sides of the fitting. These tabs are supplied for disconnecting the quick-connect fitting from component being serviced. CAUTION: The interior components (O-rings, spacers) of this type of quick-connect fitting are not serviced separately, but new plastic retainers are available. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL PRESSURE RELEASE PROCEDURE IN THIS GROUP.THIS MAY RESULT IN PERSONAL INJURY OR DEATH. DISCONNECTION/CONNECTION 1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure in this group. 2. Disconnect negative battery cable from battery or auxiliary jumper terminal. 3. Clean fitting of any foreign material before disassembly. 4. To disconnect quick-connect fitting, squeeze plastic retainer tabs against sides of quick-connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. Pull fitting from fuel system component being serviced. The plastic retainer will remain on component being serviced after fitting is disconnected. The O-rings and spacer will remain in quick-connect fitting connector body. 5. Inspect quick-connect fitting body and component for damage. Replace as necessary. CAUTION: When the quick-connect fitting was disconnected, the plastic retainer will remain on the component being serviced. If this retainer must be removed, very carefully release the retainer from the component with two small screwdrivers. After removal, inspect the retainer for cracks or any damage. 6. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 7. Insert quick-connect fitting to component being serviced and into plastic retainer. When a connection is made, a click will be heard. 8. Verify a locked condition by firmly pulling on fuel tube and fitting (15 - 30 lbs.). 9. Connect negative cable to battery or auxiliary jumper terminal. 10. Use the DRB III(R) scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. PLASTIC RETAINER RING TYPE FITTING Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions > Page 4571 Plastic Ratainer Ring Type Fitting This type of fitting can be identified by the use of a full-round plastic retainer ring (Fig. 26) usually black in color. CAUTION: The interior components (O-rings, spacers, retainers) of this type of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube assembly. WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE IN THIS GROUP.THIS MAY RESULT IN PERSONAL INJURY OR DEATH. DISCONNECTION/CONNECTION 1. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure in this section. 2. Disconnect negative battery cable from battery or auxiliary jumper terminal. 3. Clean fitting of any foreign material before disassembly. 4. To release fuel system component from quickconnect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting. With plastic ring depressed, pull fitting from component. The plastic retainer ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection. 5. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body. 6. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary. 7. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 8. Insert quick-connect fitting into component being serviced until a click is felt. 9. Verify a locked condition by firmly pulling on fuel tube and fitting (15 - 30 lbs.). 10. Connect negative battery cable to battery or auxiliary jumper terminal. 11. Use the DRB III(R) scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations Fuel Pump Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Locations > Page 4575 Fuel Pressure Regulator: Description and Operation The fuel system uses a nonadjustable pressure regulator that maintains fuel system pressure at approximately 400 ± 34 kPa (58 ± 5 psi). The fuel pressure regulator contains a diaphragm, calibrated spring and a fuel return valve. The spring pushes down on the diaphragm and closes off the fuel return port. System fuel pressure reflects the amount of fuel pressure required to open the return port. The pressure regulator is a mechanical device that is NOT controlled by the PCM or engine vacuum. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure ...................................................................................................................................... ............................... 400 kPa ± 34 kPa (58 psi ± 5 psi) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check Fuel Pressure: Testing and Inspection Fuel Delivery Check Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 4582 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 4583 Test 7 - 9 SYMPTOM CHECKING FUEL DELIVERY POSSIBLE CAUSES - Fuel pump relay - Fuel pressure out of specs - Restricted fuel supply line - Fuel pump inlet strainer plugged - Fuel pump module - Fuel delivery system operation - Fuel pump relay fused B+ circuit - (A141) fuel pump relay output circuit open - (Z1) fuel pump ground circuit open/high resistance - Fuel pump module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Delivery Check > Page 4584 Fuel Pressure: Testing and Inspection Fuel Pressure Leak Down Test Test 1 - 2 SYMPTOM CHECKING FUEL PRESSURE LEAK DOWN POSSIBLE CAUSES - Checking fuel pressure - Fuel pump module - Checking fuel leak down Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4588 Fuel Pump Relay: Description and Operation The fuel pump relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. The fuel pump relay supplies battery voltage to the fuel pump. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuel pump relay power circuit contains a fuse between the buss bar in the PDC and the relay. The fuse is located in the PDC. Refer to the Wiring Diagrams for circuit information. The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position. When the ignition switch is in the On position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Service and Repair Fuel Pump Pickup Filter: Service and Repair REMOVAL 1. Remove fuel pump module. Refer to Fuel Pump Module Removal. Inlet 2. Using a thin straight blade screwdriver, pry back the locking tabs on fuel pump reservoir and remove the strainer. 3. Remove strainer O-ring from the fuel pump reservoir body. 4. Remove any contaminants in the fuel tank by washing the inside of the fuel tank. INSTALLATION 1. Lubricate the strainer O-ring with clean engine oil. 2. Insert strainer O-ring into outlet of strainer so that it sits evenly on the step inside the outlet. 3. Push strainer onto the inlet of the fuel pump reservoir body. Make sure the locking tabs on the reservoir body lock over the locking tangs on the strainer. 4. Install fuel pump module. Refer to Fuel Pump Module Installation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair Fuel Rail: Service and Repair REMOVAL 1. Perform fuel system pressure release procedure before servicing or starting repairs. Refer to Fuel System Pressure Release Procedure. 2. Disconnect negative cable from battery. 3. Remove upper intake manifold, refer to the Engine/Manifolds/Upper Intake for more information. 4. Cover intake manifold with suitable cover when servicing. 5. Remove the fuel hose quick connect fitting from the chassis tube. Refer to Fuel Hoses, Clamps and Quick Connect Fittings. WARNING: WRAP A SHOP TOWEL AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE. Fuel Injectors 3.3/3.8L 6. Remove the fuel rail attaching bolts. 7. Remove fuel rail. Be careful not to damage the injector O-rings upon removal from their ports. INSTALLATION 1. Ensure injector holes are clean. Replace O-rings if damaged. 2. Lubricate injector O-rings with a drop of clean engine oil to ease installation. 3. Put the tip of each injector into their ports. Push the assembly into place until the injectors are seated in the ports. 4. Install the fuel rail mounting bolts. Tighten bolts to 22 N.m (200 in. lbs.) torque. 5. Remove covering on lower intake manifold and clean surface. 6. Install the Upper Intake Manifold, refer to Engine/Manifolds/Upper Intake for more information. 7. Install fuel hose quick connector fitting to chassis tubes. Refer to Fuel Hoses, Clamps and Quick Connect Fittings. Push the fitting onto the chassis tube until it clicks into place. Pull on the fitting to ensure complete insertion. 8. Connect negative cable to battery. 9. Use the DRBIII(R) scan tool to pressurize the fuel system. Check for leaks. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Filler Neck: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4604 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4605 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Filler Neck: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4611 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4612 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Page 4613 Fuel Filler Neck: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the 3 screws at the filler door. 3. Raise and support vehicle 4. Remove the left rear tire. Fuel Filler Tube (RS) Fuel Filler Tube And Vent Tube (RG) 5. Remove the splash shield. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Page 4614 Fuel Tube Vent Canister (RG) 6. Remove the canister from filler tube. 7. For Remove Disconnect the vent at the top of the filler tube. 8. Remove the ground strap. 9. Remove filler tube at tank. INSTALLATION 1. Install filler tube to tank. 2. Install the ground strap. 3. Connect the vent at the top of the filler tube. 4. Install the 3 screws at the filler door. 5. For RGInstall the canister from filler tube. 6. Install the splash shield. 7. Install the left rear tire. 8. lower vehicle. 9. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Tank Vent: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4623 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4624 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Tank Vent: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4630 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4631 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams Fule Pump Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations > Page 4639 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 4640 Idel Air Control Motor (GAS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 4641 Idle Speed/Throttle Actuator - Electronic: Description and Operation TPS/IAC 2.4L TPS/IAC 3.3/3.8L The idle air control motor is mounted on the throttle body. The PCM operates the idle air control valve. The PCM adjusts engine idle speed through the idle air control motor to compensate for engine load, coolant temperature or barometric pressure changes. The throttle body has an air bypass passage that provides air for the engine during closed throttle idle. The idle air control motor pintle protrudes into the air bypass passage. The PCM controls engine idle speed by adjusting the position of the idle air control valve. The adjustments are based on inputs the PCM receives. The inputs are from the throttle position sensor, crankshaft position sensor, coolant temperature sensor, MAP sensor, vehicle speed sensor and various switch operations (brake, park/neutral, air conditioning). When engine rpm is above idle speed, the IAC is used for the following functions: - Off-idle dashpot - Deceleration air flow control Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 4642 - A/C compressor load control (also opens the passage slightly before the compressor is engaged so that the engine rpm does not dip down when the compressor engages). Target Idle Target idle is determined by the following inputs: - Gear position - ECT Sensor - Battery voltage - Ambient/Battery Temperature Sensor - VSS - TPS - MAP Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Page 4643 Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL When servicing throttle body components, always reassemble components with new 0-rings and seals where applicable. If assembly of component is difficult, a light coat of engine oil may be applied to the 0-RINGS ONLY to aid assembly. Use care when removing hoses to prevent damage to hose or hose nipple. 1. Disconnect negative cable from battery. Idle Air Control Valve Location 2. Remove electrical connector from idle air control valve. 3. Remove idle air control motor mounting screws. 4. Remove motor from throttle body. Ensure the O-rings is removed with the valve. INSTALLATION O - Rings When servicing throttle body components, always reassemble components with new O-rings and seals where applicable. Never use lubricants on O-rings or seals, damage may result. If assembly of component is difficult, a light coat of engine oil may be applied to the O-RINGS ONLY to aid assembly. Use care when removing hoses to prevent damage to hose or hose nipple. 1. Carefully place idle air control motor into throttle body. 2. Install mounting screw. Tighten screws to 7 N.m (62 in. lbs.) torque. 3. Connect electrical connector to idle air control motor. 4. Connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4647 Main Relay (Computer/Fuel System): Diagrams Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4648 Auto Shut Down Relay Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4649 Main Relay (Computer/Fuel System): Description and Operation AUTO SHUT DOWN RELAY The relay is located in the Power Distribution Center (PDC). For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary The engine switched battery (NGC vehicles) informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is also used to power certain drivers on NGC vehicles. When energized, the ASD relay on NGC vehicles provides power to operate the injectors, ignition coil, generator field, O2 sensor heaters (both upstream and downstream), evaporative purge solenoid, EGR solenoid (if equipped) wastegate solenoid (if equipped), and NVLD solenoid (if equipped). The ASD relay also provides a sense circuit to the PCM for diagnostic purposes. If the PCM does not receive 12 volts from this input after grounding the control side of the ASD relay, it sets a Diagnostic Trouble Code (DTC). The PCM energizes the ASD any time there is an engine speed that exceeds a predetermined value (typically about 50 rpm). The ASD relay can also be energized after the engine has been turned off to perform an O2 sensor heater test, if vehicle is equipped with OBD II diagnostics. As mentioned earlier, the PCM energizes the ASD relay during an O2 sensor heater test. On NGC vehicles it checks the O2 heater upon vehicle start. The PCM still operates internally to perform several checks, including monitoring the O2 sensor heaters. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4654 Fuel Pump Relay: Description and Operation The fuel pump relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location. The fuel pump relay supplies battery voltage to the fuel pump. A buss bar in the Power Distribution Center (PDC) supplies voltage to the solenoid side and contact side of the relay. The fuel pump relay power circuit contains a fuse between the buss bar in the PDC and the relay. The fuse is located in the PDC. Refer to the Wiring Diagrams for circuit information. The PCM controls the fuel pump relay by switching the ground path for the solenoid side of the relay on and off. The PCM turns the ground path off when the ignition switch is in the Off position. When the ignition switch is in the On position, the PCM energizes the fuel pump. If the crankshaft position sensor does not detect engine rotation, the PCM de-energizes the relay after approximately one second. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4658 Main Relay (Computer/Fuel System): Diagrams Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4659 Auto Shut Down Relay Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4660 Main Relay (Computer/Fuel System): Description and Operation AUTO SHUT DOWN RELAY The relay is located in the Power Distribution Center (PDC). For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary The engine switched battery (NGC vehicles) informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is also used to power certain drivers on NGC vehicles. When energized, the ASD relay on NGC vehicles provides power to operate the injectors, ignition coil, generator field, O2 sensor heaters (both upstream and downstream), evaporative purge solenoid, EGR solenoid (if equipped) wastegate solenoid (if equipped), and NVLD solenoid (if equipped). The ASD relay also provides a sense circuit to the PCM for diagnostic purposes. If the PCM does not receive 12 volts from this input after grounding the control side of the ASD relay, it sets a Diagnostic Trouble Code (DTC). The PCM energizes the ASD any time there is an engine speed that exceeds a predetermined value (typically about 50 rpm). The ASD relay can also be energized after the engine has been turned off to perform an O2 sensor heater test, if vehicle is equipped with OBD II diagnostics. As mentioned earlier, the PCM energizes the ASD relay during an O2 sensor heater test. On NGC vehicles it checks the O2 heater upon vehicle start. The PCM still operates internally to perform several checks, including monitoring the O2 sensor heaters. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 4666 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4667 Throttle Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4668 Throttle Position Sensor: Description and Operation Throttle Position Sensor 2.4L Engine Throttle Position Sensor 3.3/3.8L Engine The throttle position sensor mounts to the side of the throttle body.The sensor connects to the throttle blade shaft. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4669 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the electrical connector from the Inlet Air Temperature sensor. 3. Remove the air cleaner box lid. Remove hose from throttle body. 4. Disconnect the electrical connector at TPS. 5. Disconnect the electrical connector at IAC. 6. Remove the throttle and speed control cables from throttle body. 7. Remove 3 mounting bolts from throttle body. 8. Remove throttle body. 9. Disconnect the purge vacuum line from the throttle body. 10. Remove TPS from throttle body. INSTALLATION 1. Install TPS to throttle body. 2. Disconnect the purge vacuum line from the throttle body. 3. Install throttle body. 4. Install 3 mounting bolts from throttle body. Tighten bolts. 5. Install the throttle and speed control cables to throttle body. 6. Connect the electrical connector at TPS. 7. Connect the electrical connector at IAC. 8. Install the air cleaner box lid. Install hose to throttle body. 9. Install the electrical connector to the Inlet Air Temperature sensor. 10. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 14-002-07 > Apr > 07 > Fuel System Throttle Body Cleaning Procedure Throttle Body: Customer Interest Fuel System - Throttle Body Cleaning Procedure NUMBER: 14-002-07 GROUP: Fuel System DATE: April 5, 2007 SUBJECT: Throttle Body Service OVERVIEW: This bulletin involves a cleaning procedure for the mechanical throttle body. MODELS: 2004 - 2006 CS Pacifica 2001 - 2007 RG Chrysler Town & Country/Dodge Caravan (International Markets) 2001 - 2007 RS Chrysler Town & Country/Dodge Caravan NOTE: This bulletin applies to CS models with a 3.5 or 3.8L engine, (sales codes EGN & EGH respectively) and RS/RG models with a 3.3 or 3.8 engine, (sales codes EGA, EGM or EGH). SYMPTOM/CONDITION: The throttle plate and bore may become coated with contaminates from the intake system. DIAGNOSIS: If the throttle body plate and bore are coated with contaminates, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the throttle body from the engine; Refer to the detailed removal procedures available in DealerCONNECT > Service > Repair > TechCONNECT > 14 - FUEL SYSTEM > FUEL INJECTION > THROTTLE BODY > REMOVAL 2. Spray the entire throttle body bore and both sides of the throttle plate with Mopar Throttle Body Cleaner, p/n 04897156AA. This will remove the bulk of the contaminant. CAUTION: This cleaner should only be used in a well ventilated area. Do not allow contact with skin or eyes. Rubber or butyl gloves and safety glasses are recommended. Wash thoroughly after use. Do not ingest. NOTE: Use only Mopar Throttle Body Cleaner, the use of other cleaning agents may damage components of the throttle body. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest for Throttle Body: > 14-002-07 > Apr > 07 > Fuel System Throttle Body Cleaning Procedure > Page 4678 3. While holding the throttle open, use a small, (1" x 1") piece of green Scotch Brite scuff pad, (or soft bristle brush), clean the throttle body bore and throttle plate, (including edges). NOTE: It is important that this cleaning procedure be performed thoroughly and completely. The edge of the throttle plate, and the portion of the throttle body bore where the throttle plate comes to rest are the most critical areas where the cleaning should be concentrated. These areas must be free of all deposits when the cleaning is completed. 4. Thoroughly clean the throttle body with Mopar Throttle Body Cleaner, p/n 04897156AA, and blow dry with compressed shop air. Inspect for any foreign material which may have been left from the cleaning process. CAUTION: Do not blow shop air pressure directly into the throttle shaft or throttle body housing holes. 5. Open and close the throttle on the throttle body to verify that there is no binding when moving off of the closed position. If the condition is corrected, proceed to the next step. If throttle still binds when moving off of the closed position, further diagnosis and/or repair will be necessary. 6. Clean all throttle body to intake manifold mounting surfaces thoroughly and install the throttle body on the engine; Refer to the detailed installation procedures available in DealerCONNECT > Service > Repair > TechCONNECT > 14 - FUEL SYSTEM > FUEL INJECTION > THROTTLE BODY > INSTALLATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 14-002-07 > Apr > 07 > Fuel System - Throttle Body Cleaning Procedure Throttle Body: All Technical Service Bulletins Fuel System - Throttle Body Cleaning Procedure NUMBER: 14-002-07 GROUP: Fuel System DATE: April 5, 2007 SUBJECT: Throttle Body Service OVERVIEW: This bulletin involves a cleaning procedure for the mechanical throttle body. MODELS: 2004 - 2006 CS Pacifica 2001 - 2007 RG Chrysler Town & Country/Dodge Caravan (International Markets) 2001 - 2007 RS Chrysler Town & Country/Dodge Caravan NOTE: This bulletin applies to CS models with a 3.5 or 3.8L engine, (sales codes EGN & EGH respectively) and RS/RG models with a 3.3 or 3.8 engine, (sales codes EGA, EGM or EGH). SYMPTOM/CONDITION: The throttle plate and bore may become coated with contaminates from the intake system. DIAGNOSIS: If the throttle body plate and bore are coated with contaminates, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove the throttle body from the engine; Refer to the detailed removal procedures available in DealerCONNECT > Service > Repair > TechCONNECT > 14 - FUEL SYSTEM > FUEL INJECTION > THROTTLE BODY > REMOVAL 2. Spray the entire throttle body bore and both sides of the throttle plate with Mopar Throttle Body Cleaner, p/n 04897156AA. This will remove the bulk of the contaminant. CAUTION: This cleaner should only be used in a well ventilated area. Do not allow contact with skin or eyes. Rubber or butyl gloves and safety glasses are recommended. Wash thoroughly after use. Do not ingest. NOTE: Use only Mopar Throttle Body Cleaner, the use of other cleaning agents may damage components of the throttle body. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 14-002-07 > Apr > 07 > Fuel System - Throttle Body Cleaning Procedure > Page 4684 3. While holding the throttle open, use a small, (1" x 1") piece of green Scotch Brite scuff pad, (or soft bristle brush), clean the throttle body bore and throttle plate, (including edges). NOTE: It is important that this cleaning procedure be performed thoroughly and completely. The edge of the throttle plate, and the portion of the throttle body bore where the throttle plate comes to rest are the most critical areas where the cleaning should be concentrated. These areas must be free of all deposits when the cleaning is completed. 4. Thoroughly clean the throttle body with Mopar Throttle Body Cleaner, p/n 04897156AA, and blow dry with compressed shop air. Inspect for any foreign material which may have been left from the cleaning process. CAUTION: Do not blow shop air pressure directly into the throttle shaft or throttle body housing holes. 5. Open and close the throttle on the throttle body to verify that there is no binding when moving off of the closed position. If the condition is corrected, proceed to the next step. If throttle still binds when moving off of the closed position, further diagnosis and/or repair will be necessary. 6. Clean all throttle body to intake manifold mounting surfaces thoroughly and install the throttle body on the engine; Refer to the detailed installation procedures available in DealerCONNECT > Service > Repair > TechCONNECT > 14 - FUEL SYSTEM > FUEL INJECTION > THROTTLE BODY > INSTALLATION. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 4685 Throttle Body: Description and Operation IAC Valve 2.4L IAC Valve Location 3.3/3.8L The throttle body is located on the intake manifold. Fuel does not enter the intake manifold through the throttle body. Fuel is sprayed into the manifold by the fuel injectors. Filtered air from the air cleaner enters the intake manifold through the throttle body. The throttle body contains an air control passage controlled by an Idle Air Control (IAC) motor. The air control passage is used to supply air for idle conditions. A throttle valve (plate) is used to supply air for above idle conditions. Certain sensors are attached to the throttle body. The accelerator pedal cable, speed control cable and transmission control cable (when equipped) are connected to the throttle body linkage arm. A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the PCM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Page 4686 Throttle Body: Service and Repair REMOVAL 1. Disconnect negative cable from battery cable. 2. Remove air inlet to throttle body hose clamp. 3. Remove throttle and the speed control (if equipped) cables from lever and bracket. IAC Valve 2.4L IAC Valve Location 3.3/3.8L 4. Disconnect electrical connectors from the idle air control motor and throttle position sensor (TPS). 5. Remove throttle body to intake manifold attaching bolts. 6. Remove throttle body and gasket. INSTALLATION 1. Install a new gasket, if required. 2. Install throttle body. 3. Tighten throttle body mounting bolts. The 2.4L to 28.2 N.m (250 ± 50 in. lbs.) torque, The 3.3/3.8L to 11.6 N.m (105 ± 20 in. lbs.) torque. 4. Connect electrical connectors to the idle air control motor and throttle position sensor (TPS). 5. Install air inlet to throttle body hose clamp and tighten. 6. Connect negative cable to battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair Throttle Cable/Linkage: Service and Repair REMOVAL 1. Working from the engine compartment, hold the throttle body throttle lever in the wide open position. 2. Remove the throttle cable from the throttle body cam. 3. From inside the vehicle, hold up the pedal and remove the cable retainer and throttle cable from the upper end of the pedal shaft. 4. Remove retainer clip from throttle cable and grommet at dash panel. 5. From the engine compartment, pull the throttle cable and gromment out of the dash panel. 6. Remove the throttle cable from throttle bracket by carefully compressing both retaining ears simultaneously then gently pull the throttle cable from throttle bracket or if it is the slide snap design you have to slide the locking tab out of the hole and then slide the cable assembly out of the bracket. INSTALLATION 1. From the engine compartment, push the housing end fitting and grommet into the dash panel. In-stall gromment into the dash panel. 2. Install the cable housing (throttle body end) into the cable mounting bracket on the engine. 3. From inside the vehicle, hold up the pedal and install throttle cable and cable retainer in the upper end of the pedal shaft. 4. At the dash panel, install the cable retainer clip between the end of the throttle cable fitting and grommet. 5. From the engine compartment, rotate the throttle lever wide open and install the throttle cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page 4694 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4695 Throttle Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4696 Throttle Position Sensor: Description and Operation Throttle Position Sensor 2.4L Engine Throttle Position Sensor 3.3/3.8L Engine The throttle position sensor mounts to the side of the throttle body.The sensor connects to the throttle blade shaft. The TPS is a variable resistor that provides the Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position. As the position of the throttle blade changes, the resistance of the TPS changes. The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the powertrain control module) represents throttle blade position. The TPS output voltage to the PCM varies from approximately 0.6 volt at minimum throttle opening (idle) to a maximum of 4.5 volts at wide open throttle. Along with inputs from other sensors, the PCM uses the TPS input to determine current engine operating conditions. The PCM also adjusts fuel injector pulse width and ignition timing based on these inputs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4697 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the electrical connector from the Inlet Air Temperature sensor. 3. Remove the air cleaner box lid. Remove hose from throttle body. 4. Disconnect the electrical connector at TPS. 5. Disconnect the electrical connector at IAC. 6. Remove the throttle and speed control cables from throttle body. 7. Remove 3 mounting bolts from throttle body. 8. Remove throttle body. 9. Disconnect the purge vacuum line from the throttle body. 10. Remove TPS from throttle body. INSTALLATION 1. Install TPS to throttle body. 2. Disconnect the purge vacuum line from the throttle body. 3. Install throttle body. 4. Install 3 mounting bolts from throttle body. Tighten bolts. 5. Install the throttle and speed control cables to throttle body. 6. Connect the electrical connector at TPS. 7. Connect the electrical connector at IAC. 8. Install the air cleaner box lid. Install hose to throttle body. 9. Install the electrical connector to the Inlet Air Temperature sensor. 10. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications Firing Order: Electrical Specifications The cylinders are numbered from the front of the engine to the rear. The front cylinder bank is numbered 2, 4, 6. The rear cylinder bank is numbered 1, 3, 5. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > Electrical Specifications > Page 4703 Firing Order: Mechanical Specifications Firing Order 1-2-3-4-5-6 .............................................................................................................................................................. ......................................... Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Number One Cylinder: Locations The cylinders are numbered from the front of the engine to the rear. The front cylinder bank is numbered 2, 4, 6. The rear cylinder bank is numbered 1, 3, 5. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 4712 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4713 Camshaft Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4714 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor EGR/CAM Sensor 2.4L The camshaft position sensor for the 3.3/3.8L is mounted in the front of the timing case cover and the camshaft position sensor for the 2.4L is mounted on the end of the cylinder head. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4715 Camshaft Position Sensor The camshaft position sensor provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it (Fig. 2). The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. Camshaft Position Sensor When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4716 Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the sensor. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs on represent which cylinder the flat spot and notches identify, they do not indicate TDC position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4717 NGC Typical Scope Patterns Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4718 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. Air Box Cover 2. Remove the air box cover and inlet tube. Camshaft Position Sensor 3. Disconnect camshaft position sensor electrical connector from the wiring harness connector. 4. Remove bolt holding sensor. 5. Rotate sensor away from block. 6. Pull sensor up out of the chain case cover. Do not pull on the sensor wiring. There is an O-ring on the body of the sensor. The O-ring may make removal difficult. A light tap to top of sensor prior to removal may reduce force needed for removal. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4719 Camshaft Position Sensor And Spacer If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. While holding the sensor in this position, install and tighten the retaining bolt 14 N.m (125 in. lbs.) torque. 4. Connect camshaft position sensor electrical connector to harness connector. 5. Install the air box cover and inlet hose. 6. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations 3.3L & 3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 4724 Crankshaft Position Sensor: Connector Locations Starter Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 4725 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4726 Crankshaft Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4727 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR Crankshaft Sensor 2.4L The 2.4L crankshaft sensor is located on the rear of the engine near the accessory drive belt. The 3.3L/3.8L crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4728 Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4729 NGC Typical Scope Patterns Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set Ignition Cable: Customer Interest Engine Controls/Ignition - MIL ON/Misfire DTC's Set NUMBER: 18-018-04 GROUP: Vehicle Performance DATE: April 27, 2004 THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD JUNE, 2004. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303, P0304, P0305, P0306 OVERVIEW: This bulletin involves replacing the spark plugs, ignition wires and if necessary, reprogramming the Powertrain Control Module with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004 (MDH 0402XX). SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC's: ^ P0300-MULTIPLE CYLINDER MISFIRE ^ P0301-CYLINDER # 1 MISFIRE ^ P0302-CYLINDER # 2 MISFIRE ^ P0303-CYLINDER # 3 MISFIRE ^ P0304-CYLINDER # 4 MISFIRE ^ P0305-CYLINDER # 5 MISFIRE ^ P0306-CYLINDER # 6 MISFIRE DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform Repair Procedure 1 and if necessary, Repair Procedure 2. If an "Authorized Modification Label" is present and states that Service Bulletin 18-016-04 has been performed, it is not necessary to perform Repair Procedure 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 4738 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE 1: Replace spark plugs and ignition cables 1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service information available in TechCONNECT or the Town & Country and Caravan service manual (publication no. 81-370-04062CD), page 8I-10. 2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2. If Service Bulletin 18-016-04 has been performed, no further action is necessary. REPAIR PROCEDURE 2: Flash Reprogram PCM NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 4739 c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select 'Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Customer Interest for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 4740 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set Ignition Cable: All Technical Service Bulletins Engine Controls/Ignition - MIL ON/Misfire DTC's Set NUMBER: 18-018-04 GROUP: Vehicle Performance DATE: April 27, 2004 THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD JUNE, 2004. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303, P0304, P0305, P0306 OVERVIEW: This bulletin involves replacing the spark plugs, ignition wires and if necessary, reprogramming the Powertrain Control Module with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004 (MDH 0402XX). SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC's: ^ P0300-MULTIPLE CYLINDER MISFIRE ^ P0301-CYLINDER # 1 MISFIRE ^ P0302-CYLINDER # 2 MISFIRE ^ P0303-CYLINDER # 3 MISFIRE ^ P0304-CYLINDER # 4 MISFIRE ^ P0305-CYLINDER # 5 MISFIRE ^ P0306-CYLINDER # 6 MISFIRE DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform Repair Procedure 1 and if necessary, Repair Procedure 2. If an "Authorized Modification Label" is present and states that Service Bulletin 18-016-04 has been performed, it is not necessary to perform Repair Procedure 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 4746 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE 1: Replace spark plugs and ignition cables 1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service information available in TechCONNECT or the Town & Country and Caravan service manual (publication no. 81-370-04062CD), page 8I-10. 2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2. If Service Bulletin 18-016-04 has been performed, no further action is necessary. REPAIR PROCEDURE 2: Flash Reprogram PCM NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 4747 c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select 'Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Cable: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 4748 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Technical Service Bulletins > Page 4749 Ignition Cable: Description and Operation SPARK PLUG CABLE Spark Plug cables are sometimes referred to as secondary ignition wires. The wires transfer electrical current from the ignition coil pack to individual spark plugs at each cylinder. The resistive spark plug cables are of nonmetallic construction. The cables provide suppression of radio frequency emissions from the ignition system. Check the spark plug cable connections for good contact at the coil, and spark plugs. Terminals should be fully seated. The insulators should be in good condition and should fit tightly on the coil, and spark plugs. Spark plug cables with insulators that are cracked or torn must be replaced. Clean Spark Plug cables with a cloth moistened with a non-flammable solvent. Wipe the cables dry. Check for brittle or cracked insulation. The spark plug cables and spark plug boots are made from high temperature materials. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 4753 Ignition Coil (3.3L/3.8L) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 4754 Ignition Coil: Description and Operation Ignition Coil - 2.4L Ignition Coil - 3.3/3.8L The ignition coil assembly consists of 2 or 3 independent coils molded together. The coil assembly for the 3.3/3.8L is mounted on the intake manifold. The coil assembly for the 2.4L is mounted on the cylinder head cover. Spark plug cables route to each cylinder from the coil. The coil fires two spark plugs every power stroke. One plug is the cylinder under compression, the other cylinder fires on the exhaust stroke. The Powertrain Control Module (PCM) determines which of the coils to charge and fire at the correct time. The Auto Shutdown (ASD) relay provides battery voltage to the ignition coil. The PCM provides a ground contact (circuit) for energizing the coil. When the PCM breaks the contact, the magnetic energy in the coil transfers to the secondary causing the spark. The PCM will de-energize the ASD relay if it does not receive the crankshaft position sensor and camshaft position sensor inputs. Refer to Auto Shutdown (ASD) Relay-PCM Output for relay operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Page 4755 Ignition Coil: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove the throttle and speed control cables from clip. 3. Remove 2 bolts from the Power steering reservoir to intake manifold. 4. Loosen the lower nut for the power steering reservoir from stud on ignition coil bracket. Ignition Coil Bracket - 3.3/3.8L 5. Reposition the Power steering reservoir. 6. Remove the ignition cables from the ignition coil. 7. Disconnect the electrical connector from the ignition coil. 8. Remove 2 nuts from the ignition coil studs. INSTALLATION 1. Install coil over studs on bracket. 2. Install 2 nuts to the ignition coil studs. Tighten nuts and bolts. 3. Connect the electrical connector to the ignition coil. 4. Install the ignition cables to the ignition coil. 5. Reposition the Power steering reservoir. Slide bracket over the mounting stud. 6. Install 2 bolts to the Power steering reservoir to intake manifold. 7. Tighten the lower nut to stud on ignition coil bracket. 8. Install the throttle and speed control cables to clip. 9. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Shut Down Relay (For Antitheft) > Component Information > Description and Operation Ignition Shut Down Relay (For Antitheft): Description and Operation AUTO SHUT DOWN RELAY The relay is located in the Power Distribution Center (PDC). For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary The engine switched battery (NGC vehicles) informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is also used to power certain drivers on NGC vehicles. When energized, the ASD relay on NGC vehicles provides power to operate the injectors, ignition coil, generator field, O2 sensor heaters (both upstream and downstream), evaporative purge solenoid, EGR solenoid (if equipped) wastegate solenoid (if equipped), and NVLD solenoid (if equipped). The ASD relay also provides a sense circuit to the PCM for diagnostic purposes. If the PCM does not receive 12 volts from this input after grounding the control side of the ASD relay, it sets a Diagnostic Trouble Code (DTC). The PCM energizes the ASD any time there is an engine speed that exceeds a predetermined value (typically about 50 rpm). The ASD relay can also be energized after the engine has been turned off to perform an O2 sensor heater test, if vehicle is equipped with OBD II diagnostics. As mentioned earlier, the PCM energizes the ASD relay during an O2 sensor heater test. On NGC vehicles it checks the O2 heater upon vehicle start. The PCM still operates internally to perform several checks, including monitoring the O2 sensor heaters. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation The knock sensor threads into the cylinder block. The knock sensor is designed to detect engine vibration that is caused by detonation. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives as an input the knock sensor voltage signal. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except WOT. The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Shut Down Relay (For Antitheft) > Component Information > Description and Operation Ignition Shut Down Relay (For Antitheft): Description and Operation AUTO SHUT DOWN RELAY The relay is located in the Power Distribution Center (PDC). For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary The engine switched battery (NGC vehicles) informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is also used to power certain drivers on NGC vehicles. When energized, the ASD relay on NGC vehicles provides power to operate the injectors, ignition coil, generator field, O2 sensor heaters (both upstream and downstream), evaporative purge solenoid, EGR solenoid (if equipped) wastegate solenoid (if equipped), and NVLD solenoid (if equipped). The ASD relay also provides a sense circuit to the PCM for diagnostic purposes. If the PCM does not receive 12 volts from this input after grounding the control side of the ASD relay, it sets a Diagnostic Trouble Code (DTC). The PCM energizes the ASD any time there is an engine speed that exceeds a predetermined value (typically about 50 rpm). The ASD relay can also be energized after the engine has been turned off to perform an O2 sensor heater test, if vehicle is equipped with OBD II diagnostics. As mentioned earlier, the PCM energizes the ASD relay during an O2 sensor heater test. On NGC vehicles it checks the O2 heater upon vehicle start. The PCM still operates internally to perform several checks, including monitoring the O2 sensor heaters. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations 3.3L/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Component Locations > Page 4771 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4772 Camshaft Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4773 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor EGR/CAM Sensor 2.4L The camshaft position sensor for the 3.3/3.8L is mounted in the front of the timing case cover and the camshaft position sensor for the 2.4L is mounted on the end of the cylinder head. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4774 Camshaft Position Sensor The camshaft position sensor provides cylinder identification to the Powertrain Control Module (PCM). The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it (Fig. 2). The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses. Camshaft Position Sensor When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after cylinder 5 signals cylinder 6. The PCM can synchronize on cylinders 1 or 4. When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the voltage switches from low (metal) to high (notch) then back to low. The number of notches determine the amount of pulses. If available, an oscilloscope can display the square wave patterns of each timing event. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4775 Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the sensor. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses associated with the particular cylinder. The arrows and cylinder call outs on represent which cylinder the flat spot and notches identify, they do not indicate TDC position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4776 NGC Typical Scope Patterns Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4777 Camshaft Position Sensor: Service and Repair REMOVAL 1. Disconnect the negative battery cable. Air Box Cover 2. Remove the air box cover and inlet tube. Camshaft Position Sensor 3. Disconnect camshaft position sensor electrical connector from the wiring harness connector. 4. Remove bolt holding sensor. 5. Rotate sensor away from block. 6. Pull sensor up out of the chain case cover. Do not pull on the sensor wiring. There is an O-ring on the body of the sensor. The O-ring may make removal difficult. A light tap to top of sensor prior to removal may reduce force needed for removal. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4778 Camshaft Position Sensor And Spacer If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW SPACER must be attached to the face before installation. Inspect O-ring for damage, replace if necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face and O-ring is positioned in groove of the new sensor. 1. Apply a couple drops of clean engine oil to the O-ring prior to installation. 2. Install sensor in the chain case cover and rotate into position. 3. Push sensor down until contact is made with the camshaft gear. While holding the sensor in this position, install and tighten the retaining bolt 14 N.m (125 in. lbs.) torque. 4. Connect camshaft position sensor electrical connector to harness connector. 5. Install the air box cover and inlet hose. 6. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations Crankshaft Position Sensor: Component Locations 3.3L & 3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 4783 Crankshaft Position Sensor: Connector Locations Starter Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Component Locations > Page 4784 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4785 Crankshaft Position Sensor (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4786 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION SENSOR Crankshaft Sensor 2.4L The 2.4L crankshaft sensor is located on the rear of the engine near the accessory drive belt. The 3.3L/3.8L crankshaft sensor is located on the rear of the transmission housing, above the differential housing. The bottom of the sensor is positioned next to the drive plate. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4787 Timing Slots The crankshaft position sensor detects slots cut into the transmission driveplate extension. There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots. Basic timing is set by the position of the last slot in each group. Once the Powertrain Control Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine revolution to determine crankshaft position. The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the injectors in sequence. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4788 NGC Typical Scope Patterns Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation KEY/LOCK CYLINDER DESCRIPTION The lock cylinder is inserted in the end of the housing opposite the ignition switch. OPERATION The ignition key rotates the cylinder to 5 different detents (Fig. 30): Accessory - Off (lock) - Unlock - On/Run - Start Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 4793 Ignition Switch Lock Cylinder: Service and Repair Key/Lock Cylinder REMOVAL 1. Disconnect negative cable from battery. 2. Remove steering column cover retaining screws. 3. Remove screws holding steering column shrouds and remove lower shroud. 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab on the bottom of the lock housing and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position (Fig. 31). 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6. Install steering column cover. 7. Connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation The knock sensor threads into the cylinder block. The knock sensor is designed to detect engine vibration that is caused by detonation. When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives as an input the knock sensor voltage signal. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except WOT. The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening affects knock sensor performance, possibly causing improper spark control. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set Spark Plug: Customer Interest Engine Controls/Ignition - MIL ON/Misfire DTC's Set NUMBER: 18-018-04 GROUP: Vehicle Performance DATE: April 27, 2004 THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD JUNE, 2004. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303, P0304, P0305, P0306 OVERVIEW: This bulletin involves replacing the spark plugs, ignition wires and if necessary, reprogramming the Powertrain Control Module with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004 (MDH 0402XX). SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC's: ^ P0300-MULTIPLE CYLINDER MISFIRE ^ P0301-CYLINDER # 1 MISFIRE ^ P0302-CYLINDER # 2 MISFIRE ^ P0303-CYLINDER # 3 MISFIRE ^ P0304-CYLINDER # 4 MISFIRE ^ P0305-CYLINDER # 5 MISFIRE ^ P0306-CYLINDER # 6 MISFIRE DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform Repair Procedure 1 and if necessary, Repair Procedure 2. If an "Authorized Modification Label" is present and states that Service Bulletin 18-016-04 has been performed, it is not necessary to perform Repair Procedure 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 4805 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE 1: Replace spark plugs and ignition cables 1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service information available in TechCONNECT or the Town & Country and Caravan service manual (publication no. 81-370-04062CD), page 8I-10. 2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2. If Service Bulletin 18-016-04 has been performed, no further action is necessary. REPAIR PROCEDURE 2: Flash Reprogram PCM NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 4806 c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select 'Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > Customer Interest for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 4807 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set Spark Plug: All Technical Service Bulletins Engine Controls/Ignition - MIL ON/Misfire DTC's Set NUMBER: 18-018-04 GROUP: Vehicle Performance DATE: April 27, 2004 THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD JUNE, 2004. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303, P0304, P0305, P0306 OVERVIEW: This bulletin involves replacing the spark plugs, ignition wires and if necessary, reprogramming the Powertrain Control Module with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004 (MDH 0402XX). SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC's: ^ P0300-MULTIPLE CYLINDER MISFIRE ^ P0301-CYLINDER # 1 MISFIRE ^ P0302-CYLINDER # 2 MISFIRE ^ P0303-CYLINDER # 3 MISFIRE ^ P0304-CYLINDER # 4 MISFIRE ^ P0305-CYLINDER # 5 MISFIRE ^ P0306-CYLINDER # 6 MISFIRE DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform Repair Procedure 1 and if necessary, Repair Procedure 2. If an "Authorized Modification Label" is present and states that Service Bulletin 18-016-04 has been performed, it is not necessary to perform Repair Procedure 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 4813 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE 1: Replace spark plugs and ignition cables 1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service information available in TechCONNECT or the Town & Country and Caravan service manual (publication no. 81-370-04062CD), page 8I-10. 2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2. If Service Bulletin 18-016-04 has been performed, no further action is necessary. REPAIR PROCEDURE 2: Flash Reprogram PCM NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 4814 c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select 'Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Spark Plug: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 4815 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Electrical Specifications Spark Plug Resistance - 3.3/3.8L Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Electrical Specifications > Page 4818 Spark Plug: Mechanical Specifications Spark Plug - 3.3L/3.8L Torque Spark Plug Torque ............................................................................................................................... ................................................ 13 ft. lbs. (17.5 N.m) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4819 Spark Plug: Application and ID Spark Plug Type .................................................................................................................................. .................................................................RE14PLP5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4820 Spark Plug: Description and Operation STANDARD 4 CYLINDER All engines use resistor spark plugs. They have resistance values ranging from 6,000 to 20,000 ohms when checked with at least a 1000 volt spark plug tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Refer to Specifications for gap and type of spark plug. PLATINUM PLUGS The V6 engines use platinum resistor spark plugs. They have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. For spark plug identification and specifications, refer to Specifications. Do not use man ohm meter to check the resistance of the spark plugs. This will give an inaccurate reading. Platinum Pads Setting Spark Electrode Gap When the spark plugs use a single or double platinum tips and they have a recommended service life of 100,000 miles for normal driving conditions per Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4821 schedule A. The spark plugs have a recommended service life of 75,000 miles for severe driving conditions per schedule B. A thin platinum pad is welded to both or just the center electrode end(s) as shown. Extreme care must be used to prevent spark plug cross threading, mis-gapping and ceramic insulator damage during plug removal and installation. CAUTION: Cleaning of the platinum plug may damage the platinum tip. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4822 Spark Plug: Service and Repair REMOVAL When replacing the spark plugs and spark plug cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. Always remove cables by grasping at the boot, rotating the boot 1/2 turn, and pulling straight back in a steady motion. 1. Prior to removing the spark plug, spray compressed air around the spark plug hole and the area around the spark plug. 2. Remove the spark plug using a quality socket with a foam insert. 3. Inspect the spark plug condition. INSTALLATION When replacing the spark plugs and spark plug cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise, cross ignition of the spark plugs or short circuit the cables to ground. 1. Coat threads of spark plug with anti-seize. Be sure not to get anti-seize ANYWHERE BUT ON THE THREADS OF THE SPARK PLUG as shown. 2. To avoid cross threading, start the spark plug into the cylinder head by hand. 3. Tighten spark plugs to 17.5 N.m (13 ft. lbs.) torque. 4. Install spark plug cables over spark plugs. A click will be heard and felt when the cable properly attaches to the spark plug. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation Pressure Regulating Solenoid: Description and Operation SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION The Solenoid/Pressure Switch Assembly (Fig. 276) is external to the transaxle and mounted to the transaxle case. The assembly consists of four solenoids that control hydraulic pressure to the LR/CC, 2/4, OD, and UD friction elements. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the PCM/TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The PCM/TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which by design allow fluid to pass through in their relaxed or "off" state. This allows transaxle limp-in (P, R, N, 2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the PCM/TCM during this test. It no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The PCM/TCM relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the PCM/TCM detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the PCM/TCM for the correct states (open or closed) in each gear as shown in the following chart: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 4829 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the PCM/TCM senses any switch open or closed at the wrong time in a given gear. The PCM/TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the PCM/TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 4830 Pressure Regulating Solenoid: Service and Repair SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect solenoid/pressure switch assembly connector (Fig. 277). 4. Disconnect input speed sensor connector (Fig. 277). 5. Remove input speed sensor (Fig. 278). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 4831 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 279). 7. Remove solenoid/pressure switch assembly and gasket (Fig. 280). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 280). 2. Install and torque three (3) bolts (Fig. 279) to 13 Nm (110 inch lbs.). 3. Install input speed sensor (Fig. 278) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector (Fig. 277). 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 inch lbs.) (Fig. 277). 6. Install air cleaner assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4835 Steering Column Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4836 Brake Transmission shift Interlock Solenoid Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4837 Shift Interlock Solenoid: Service and Repair SHIFT INTERLOCK SOLENOID REMOVAL 1. Disconnect battery negative cable. 2. Remove instrument panel lower shroud (Fig. 268). 3. Remove knee bolster (Fig. 269). 4. Remove steering column lower shroud. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4838 5. Disconnect Brake/Transmission Shift Interlock (BTSI) solenoid connector (Fig. 270). 6. Remove two (2) solenoid-to-column screws (Fig. 271). 7. Remove solenoid. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4839 1. Place interlock solenoid into position ensuring hook on end of solenoid plunger engages gearshift lever pawl pin. Install and tighten screws (Fig. 272). 2. Verify gearshift lever is in PARK (P) and connect solenoid connector (Fig. 273). 3. Install steering column lower shroud. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4840 4. Install knee bolster (Fig. 274). 5. Install instrument panel lower silencer (Fig. 275). 6. Connect battery negative cable. 7. Verify proper shift interlock system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications 41TE - Automatic Transaxle SOLENOID/PRESSURE SWITCH ASSY Bolt, Solenoid/Pressure Switch Assy. Connector .............................................................................................................................. 12 Nm (110 inch lbs.) Screw, Solenoid/Pressure Switch Assy. Connector ............................................................................................................................... 4 Nm (35 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4844 Shift Solenoid: Locations Transmission Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4845 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4846 Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4847 Transmission Solenodi/pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4848 Shift Solenoid: Description and Operation 41TE - Automatic Transaxle SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION The Solenoid/Pressure Switch Assembly (Fig. 313) is external to the transaxle and mounted to the transaxle case. The assembly consists of four solenoids that control hydraulic pressure to the LR/CC, 2/4, OD, and UD friction elements. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which by design allow fluid to pass through in their relaxed or "off" state. This allows transaxle limp-in (P, R, N, 2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. It no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11 - 23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following chart: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4849 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4850 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4851 Shift Solenoid: Service and Repair 41TE - Automatic Transaxle SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect solenoid/pressure switch assembly connector. 4. Disconnect input speed sensor connector. 5. Remove input speed sensor (Fig. 314). 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 315). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4852 7. Remove solenoid/pressure switch assembly and gasket (Fig. 316). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 316). 2. Install and torque three (3) bolts (Fig. 315) to 13 Nm (110 inch lbs.). 3. Install input speed sensor (Fig. 314) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector. 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 inch lbs.). 6. Install air cleaner assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations Control Module: Locations Control Module Locations NGC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4858 Control Module: Description and Operation Fig.14 Transmission Control Module (TCM) Location The Transmission Control Module (TCM) is located behind the left fender and is fastened with three screws to three clips in the left frame rail forward of the suspension (Fig. 14). The TCM is the controlling unit for all electronic operations of the transaxle. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transaxle. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the J1850 communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor (CKP) - Transmission Range Sensor (TRS) - Pressure Switches (L/R, 2/4, OD) - Transmission Temperature Sensor (Integral to TRS) - Input Shaft Speed Sensor - Output Shaft Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Speed Control ON/OFF Switch - Engine Coolant Temperature - Ambient/Battery Temperature - Brake Switch Status - DRB Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids (LR/CC, 2/4, OD and UD) - Vehicle Speed (to PCM) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4859 - Torque Reduction Request (to PCM) An example of a TCM indirect output is: - Transmission Temperature (to PCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indices (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB scan tool) Clutch Volume Index (CVI) An important function of the TCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.15 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transaxle gear ratio. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 15). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4860 Clutch Volumes Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4861 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 4862 Control Module: Service and Repair ELECTRONIC PINION FACTOR (IF APPLICABLE) NOTE: After replacing the EATX/PCM, you must reprogram pinion factor. In some vehicle applications, the pinion factor is a fixed value and cannot be changed or updated. The transmission output speed signal supplies distance pulses to the control module, which are used to calculate speed and mileage. A pinion factor is stored in the control module in order to provide the appropriate distance pulses for other vehicle systems. The pinion factor is programmed into the control module at the assembly plant. The pinion factor must be set when replacing the control module. If the pinion factor is not set or incorrectly set, any speed related functions will not operate correctly i.e. speedometer, speed control, rolling door locks, other control modules will be affected that depend on speed information. Using the following steps, the pinion factor can be checked and/or reset using the DRBIII: 1. Select Transmission system, then Miscellaneous functions, then Pinion Factor. The DRBIII will display the current tire size. 2. If the tire size is incorrect, press the Enter key and then select the correct size. 3. Press the Page Back key to exit the reset procedure. Notes About Electronic Pinion Factor Features The nature of the electronic pinion factor requires that certain features must be taken into consideration. ^ If no pinion factor is stored in an installed control module, the vehicle speedometer will not operate, engine speed will be limited to 2300 RPM, and catalyst damage may occur. ^ Selecting a wrong tire size will cause the speedometer to be inaccurate and will also cause any speed related features to operate improperly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4866 Transmission Control System Relay: Diagrams Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4867 Transmission Control Relay (EATX) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Transmission Control System Relay: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION CONTROL RELAY - DESCRIPTION The transmission control relay (Fig. 336) is located in the Intelligent Power Module (IPM), which is located on the left side of the engine compartment between the battery and left fender. OPERATION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 4870 Transmission Control System Relay: Description and Operation 40TE Automatic Transaxle TRANSMISSION CONTROL RELAY DESCRIPTION The transmission control relay (Fig. 302) is located in the Intelligent Power Module (IPM), which is located on the left side of the engine compartment between the battery and left fender. OPERATION The Transmission Control Relay is supplied fused B+ voltage, energized by the PCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the PCM energizes the relay. Prior to this, the PCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the PCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Testing and Inspection > Pressure Switch States Pressure Switch States Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Testing and Inspection > Pressure Switch States > Page 4878 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR Sensor, Transmission Range Sensor ...................................................................................................................................................... 5 Nm (45 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 4884 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4885 Transmission Range Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 337). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 338). OPERATION The Transmission Range Sensor (TRS) (Fig. 337) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 4888 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 338) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 4889 Transmission Position Switch/Sensor: Description and Operation 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 303). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM/TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 304). OPERATION The Transmission Range Sensor (TRS) (Fig. 303) communicates Shift Lever Position (SLP) to the PCM/TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the PCM/TCM receives from four sense circuits. The PCM/TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the PCM/TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 4890 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 304) that the PCM/TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the PCM/TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the PCM/TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 4891 Transmission Position Switch/Sensor: Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle Transmission Position Switch/Sensor: Service and Repair 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 305). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 305) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 4894 Transmission Position Switch/Sensor: Service and Repair 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 339). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 339) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 4895 Transmission Position Switch/Sensor: Service and Repair 41TE REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 343). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 343) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications 41TE - Automatic Transmission Sensor, Input Speed ............................................................................................................................ .................................................... 27 Nm (20 ft. lbs.) Sensor, Output Speed ...................................... ........................................................................................................................................ 27 Nm (20 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 4901 Transmission Speed Sensor: Connector Locations Transmission Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 4902 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4903 Transmission Speed Sensor: Diagrams Input Speed Sensor Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle Transmission Speed Sensor: Description and Operation 40TE Automatic Transaxle Speed Sensor Input INPUT SPEED SENSOR DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case. The Input Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 4906 The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as input shaft rpm. The PCM/TCM compares the input speed signal with output speed signal to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The PCM/TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Speed Sensor Output OUTPUT SPEED SENSOR DESCRIPTION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 4907 The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case. The Output Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as output shaft rpm. The PCM/TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation Vehicle Speed Signal The vehicle speed signal is taken from the Output Speed Sensor. The PCM converts this signal into a pulse per mile and sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 4908 Transmission Speed Sensor: Description and Operation 41TE Automatic Transmission Input Speed Sensor INPUT SPEED SENSOR DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case. The Input Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 4909 The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as input shaft rpm. The PCM/TCM compares the input speed signal with output speed signal to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The PCM/TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Output Speed Sensor OUTPUT SPEED SENSOR DESCRIPTION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 4910 The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case. The Output Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as output shaft rpm. The PCM/TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation Vehicle Speed Signal The vehicle speed signal is taken from the Output Speed Sensor. The PCM converts this signal into a pulse per mile and sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle Transmission Speed Sensor: Service and Repair 40TE Automatic Transaxle Input Speed Sensor SPEED SENSOR INPUT REMOVAL 1. Disconnect battery negative cable. 2. Disconnect input speed sensor connector (Fig. 284). 3. Unscrew and remove input speed sensor (Fig. 285). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 4913 4. Inspect speed sensor o-ring (Fig. 286) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 286). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.) (Fig. 285). 3. Connect speed sensor connector (Fig. 284). 4. Connect battery negative cable. Output Speed Sensor SPEED SENSOR OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector (Fig. 290). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 4914 4. Unscrew and remove output speed sensor (Fig. 291). 5. Inspect speed sensor o-ring (Fig. 292) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 292). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector (Fig. 290). 4. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 4915 Transmission Speed Sensor: Service and Repair 41TE Automatic Transmission Input Speed Sensor SPEED SENSOR INPUT REMOVAL 1. Disconnect battery negative cable. 2. Disconnect input speed sensor connector (Fig. 284). 3. Unscrew and remove input speed sensor (Fig. 285). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 4916 4. Inspect speed sensor o-ring (Fig. 286) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 286). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.) (Fig. 285). 3. Connect speed sensor connector (Fig. 284). 4. Connect battery negative cable. Output Speed Sensor SPEED SENSOR OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector (Fig. 290). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 4917 4. Unscrew and remove output speed sensor (Fig. 291). 5. Inspect speed sensor o-ring (Fig. 292) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 292). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector (Fig. 290). 4. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 4921 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-018-07A > Dec > 07 > Engine, A/T Controls - Harsh 1-2/2-3 A/T Shifts PROM - Programmable Read Only Memory: Customer Interest Engine, A/T Controls - Harsh 1-2/2-3 A/T Shifts NUMBER: 21-018-07 REV. A GROUP: Transmission DATE: December 12, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-018-07, DATED OCTOBER 27, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL SOFTWARE FOR THE EARLY BUILD 2005 MODELS. THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL ALSO BE AVAILABLE ON ITIL/ISIS DVD JANUARY, 2008. SUBJECT: Flash: 1 - 2 and/or 2 - 3 Shift Harshness OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software and performing the Quicklearn procedure with the DRBIII(R). MODELS: 2005 - 2006 (RG) Chrysler Voyager (International Markets) 2005 - 2006 (RS) Town & Country/Voyager/Caravan NOTE: **This bulletin applies to models equipped with a 3.3L or 3.8L engine (sales code EGA, EGM or EGH)**. SYMPTOM/CONDITION: Some customers may experience 1 - 2 and/or 2 - 3 shift harshness. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) and appropriate Diagnostic Procedures available in DealerCONNECT > TechCONNECT, verify all transmission systems are functioning as designed. If the vehicle operator describes the Symptom/Conditions and / or they can be verified, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-018-07A > Dec > 07 > Engine, A/T Controls - Harsh 1-2/2-3 A/T Shifts > Page 4930 NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII® connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display". f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is finished, complete the remaining steps. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 21-018-07A > Dec > 07 > Engine, A/T Controls - Harsh 1-2/2-3 A/T Shifts > Page 4931 NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. 13. With the DRBIII(R) perform the Quicklearn procedure. NOTE: The following step is required by U.S. law. 14. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-004-07 > Jan > 07 > Engine Controls - MIL ON/DTC P0480 Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC P0480 Set NUMBER: 18-004-07 GROUP: Vehicle Performance DATE: January 24, 2007 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. SUBJECT: Flash: MIL DTC P0480-Cooling Fan 1 Control Circuit OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2005-2006 (RS) Caravan/Town & Country NOTE: This bulletin applies to vehicles equipped with a 3.3 or 3.8L engine (sales code EGA and EGH). SYMPTOM/CONDITION: Customer may experience MIL illumination. Lack of fan operation may be noted. This may occur when previous drive cycles occurred in heavy snow conditions causing snow and/or ice to form at the base of the fan shroud blocking the fan blade. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than P0480 are present record them on the repair order and repair as necessary before proceeding further with this bulletin. After performing the diagnostic procedures available in TechCONNEGT listed for P0480, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE USING DRBIII(R) AND DOWNLOADING THE FLASH FILE FROM DealerCONNECT > Tech TOOLS: NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-004-07 > Jan > 07 > Engine Controls - MIL ON/DTC P0480 Set > Page 4936 Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2007 Diagnostics". c. "All (Except Below)". d. "Engine". e. "Module Display". f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-004-07 > Jan > 07 > Engine Controls - MIL ON/DTC P0480 Set > Page 4937 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. NOTE: The following step is required by law. 15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls - MIL ON/DTC P0135 Set NUMBER: 18-010-05 REV. A GROUP: Vehicle Performance DATE: March 4, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-010-05, DATED FEBRUARY 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN UPDATED VEHICLE BUILD DATE. THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD APRIL, 2005. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DIG) P0135 - 02 Sensor 1/1 Heater Performance OVERVIEW: This bulletin involves verifying the proper 1/1 02 Sensor is installed on the vehicle and reprogramming the Powertrain Control Module with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager NOTE: **This bulletin applies to 2005 CS and RS vehicles equipped with a 3.8L engine (sales code EGH) built on and between July 8, 2004 (MDH 0708XX) and March 2, 2005 (MDH 0302XX). 2005 RS vehicles equipped with a 3.3L engine (sales code EGA, EGM and EGH) built on and between July 8, 2004 (MDH 0708XX) and October 29, 2004 (MDH 1029XX).** SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by the following Diagnostic Trouble Codes (DTC's): P0135 - 02 Sensor 1/1 Heater Performance DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than the one listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. Verify that the correct 02 Sensor is installed on the vehicle. Refer to Service Bulletin 08-008-05. Installing an incorrect 1/1 02 sensor will cause a MIL illumination for DTC P0135 - 02 Sensor 1/1 Heater Performance to be set. If the vehicle operator describes or experiences the Symptom/Condition and the correct 1/1 02 sensor is installed on the vehicle, perform the Repair Procedure. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 4942 SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 4943 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set PROM - Programmable Read Only Memory: Customer Interest Engine Controls/Ignition - MIL ON/Misfire DTC's Set NUMBER: 18-018-04 GROUP: Vehicle Performance DATE: April 27, 2004 THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD JUNE, 2004. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303, P0304, P0305, P0306 OVERVIEW: This bulletin involves replacing the spark plugs, ignition wires and if necessary, reprogramming the Powertrain Control Module with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004 (MDH 0402XX). SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC's: ^ P0300-MULTIPLE CYLINDER MISFIRE ^ P0301-CYLINDER # 1 MISFIRE ^ P0302-CYLINDER # 2 MISFIRE ^ P0303-CYLINDER # 3 MISFIRE ^ P0304-CYLINDER # 4 MISFIRE ^ P0305-CYLINDER # 5 MISFIRE ^ P0306-CYLINDER # 6 MISFIRE DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform Repair Procedure 1 and if necessary, Repair Procedure 2. If an "Authorized Modification Label" is present and states that Service Bulletin 18-016-04 has been performed, it is not necessary to perform Repair Procedure 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 4948 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE 1: Replace spark plugs and ignition cables 1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service information available in TechCONNECT or the Town & Country and Caravan service manual (publication no. 81-370-04062CD), page 8I-10. 2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2. If Service Bulletin 18-016-04 has been performed, no further action is necessary. REPAIR PROCEDURE 2: Flash Reprogram PCM NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 4949 c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select 'Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 4950 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-04 > Apr > 04 > Engine Controls - Warm Engine Rough Idle PROM - Programmable Read Only Memory: Customer Interest Engine Controls - Warm Engine Rough Idle NUMBER: 18-016-04 GROUP: Vehicle Performance DATE: April 13, 2004 THE SOFTWARE WILL BE AVAILABLE ON TechCONNECT APRIL 13, 2004. SUBJECT: Flash: Rough Idle When Engine Is At Normal Operating Temperature OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan/Voyager NOTE: This bulletin applies to vehicles equipped with a 3.3L or 3.8L engine (sales code EGA, EGH or EGM) built on or before April 2, 2004. SYMPTOM/CONDITION: The vehicle operator may describe a rough idle after the engine has warmed up to normal operating temperature. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R), must be programmed with the latest revision level available. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-04 > Apr > 04 > Engine Controls - Warm Engine Rough Idle > Page 4955 NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRB III(R) reboots to the MAIN MENU, proceed to (STEP # 2) 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in (STEP # 2) in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII(R)" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to (STEP # 9). 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to (STEP # 13). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 18-016-04 > Apr > 04 > Engine Controls - Warm Engine Rough Idle > Page 4956 13. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-018-07A > Dec > 07 > Engine, A/T Controls - Harsh 1-2/2-3 A/T Shifts PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine, A/T Controls Harsh 1-2/2-3 A/T Shifts NUMBER: 21-018-07 REV. A GROUP: Transmission DATE: December 12, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-018-07, DATED OCTOBER 27, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL SOFTWARE FOR THE EARLY BUILD 2005 MODELS. THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL ALSO BE AVAILABLE ON ITIL/ISIS DVD JANUARY, 2008. SUBJECT: Flash: 1 - 2 and/or 2 - 3 Shift Harshness OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software and performing the Quicklearn procedure with the DRBIII(R). MODELS: 2005 - 2006 (RG) Chrysler Voyager (International Markets) 2005 - 2006 (RS) Town & Country/Voyager/Caravan NOTE: **This bulletin applies to models equipped with a 3.3L or 3.8L engine (sales code EGA, EGM or EGH)**. SYMPTOM/CONDITION: Some customers may experience 1 - 2 and/or 2 - 3 shift harshness. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) and appropriate Diagnostic Procedures available in DealerCONNECT > TechCONNECT, verify all transmission systems are functioning as designed. If the vehicle operator describes the Symptom/Conditions and / or they can be verified, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-018-07A > Dec > 07 > Engine, A/T Controls - Harsh 1-2/2-3 A/T Shifts > Page 4962 NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII® connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display". f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify that charging rate provides approximately 13.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is finished, complete the remaining steps. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 21-018-07A > Dec > 07 > Engine, A/T Controls - Harsh 1-2/2-3 A/T Shifts > Page 4963 NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. 13. With the DRBIII(R) perform the Quicklearn procedure. NOTE: The following step is required by U.S. law. 14. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Programming Generic PCMs NUMBER: 18-029-07 GROUP: Vehicle Performance DATE: April 26, 2007 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-006-04 REV. B, DATED SEPTEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A MINOR REVISION AND **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT UPDATED PL PARTS APPLICATIONS. SUBJECT: Generic Powertrain Control Module (PCM) Procedure OVERVIEW: This bulletin involves programming a generic PCM with software. MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR) Ram Truck 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004-2005 (KJ) Liberty 2004 - 2005 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2004-2005 (PL) Neon 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2005 (TJ) Wrangler Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 4968 NOTE: Refer to the table for specific applications. DISCUSSION: Mopar(R) is currently phasing out pre-programmed PCMs for the vehicles listed. New modules will no longer be pre-programmed when received from Mopar(R). Replacement of future PCMs will require programming utilizing the DRBIII(R) and TechCONNECT. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 4969 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 4970 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 4971 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 4972 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 4973 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: When flashing a 2002 - 2004 LH vehicle the BCM may need to be disconnected if experiencing failures during the flash of the transmission portion of the PCM. The BCM will need to be disconnected after the module ID portion of the flash is complete. Before pressing Page Forward to begin the flash of the PCM Turn the Key to the OFF position and disconnect the BCM. Then turn the KEY to the RUN position and Press Page Forward to begin the PCM flash session. NOTE: If vehicle is a DAKOTA, then the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for any erroneous DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRB III(R) reboots to the MAIN MENU, proceed to Step 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 4974 NOTE: If your vehicle is a 2002 LH and the original PCM part number begins with 04 the technician should use the 2002 LH Part Number Reference chart above to determine the corresponding "NEW" part number. This new number from the chart should then be entered into the Tech tools application as the original part number. If the original PCM number begins with 05 no change to the flash selection process is required. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the first ten (10) characters of the "PCM part # " on the repair order for later reference. NOTE: If the PCM is not operational, the part number can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step. 3. Page back to the "Main Menu" 4. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. 5. If the vehicle is not equipped with SKIM then proceed to step 6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with step 6. This information is available from one of the following: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. CAUTION: Failure to install the SKIM pin number into the module after flashing the PCM will cause a start and stall condition. 6. Replace the PCM using the appropriate generic control module. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E, Electronic Control Modules, Powertrain Control Module, Removal/Installation. 7. Open the hood, install a battery charger and verify battery state is above 11.5 volts. 8. If the old "PCM part # " is known, proceed to step 14. If the old "PCM part # " is not known, proceed to next step. 9. On DealerCONNECT select the "Service" tab. 10. Select "Vehicle Information Plus". 11. Manually enter the VIN and mileage and select "Enter". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 4975 12. Select the "Vehicle Option" tab. 13. Under the "Vehicle Option window, identify and record: a. Engine. b. Emissions (Federal or California). c. Transmission (Automatic, 5-speed manual, etc.). 14. Connect the DRBIII(R) to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 15. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates. NOTE: Do NOT enter the generic controller part number in step 16a below. 16. Determine the proper calibration: a. If the old "PCM part # " is known, enter the part number of the old controller in the "Parts Criteria p/n window. Proceed to step 16. b. If the old "PCM part # " is not known, select the correct calibration based on the information that was recorded from "Vehicle Options" in step 13. 17. Select the correct calibration. 18. Select the "Download/Update button. 19. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII(R). When the flash process is completed, proceed to next step. 20. Enter the VIN in the PCM. Using the DRBIII® select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "Engine" e. "Miscellaneous" f. "Check VIN" g. If the vehicle is not equipped with SKIM proceed to step 20h. If the vehicle is equipped with SKIM follow the directions on the DRBIII(R). When the VIN and SKIM key has been programmed, proceed to step 20. h. Enter the VIN as requested by the DRBIII(R). 21. Update the PCM mileage. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Check PCM Odometer" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 4976 g. "NO" h. Enter the current odometer mileage and then press "Enter". i. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter". 22. Proceed as follows: a. If the vehicle is equipped with an automatic transmission, proceed to step 24. b. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 24. c. If the vehicle is equipped with a Turbo engine and manual transmission, proceed to step 23. 23. On vehicles equipped with a Turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII® Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Pinion Factor" g. Select the correct tire size and then select "Page Back" to exit. h. Proceed to step 24. 24. On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Transmission" e. "Transmission Module" f. "Miscellaneous" g. "Pinion Factor" h. Select the correct tire size and then select "Page Back" to exit. i. Enter "Quick Learn" and then follow the instructions on the DRBIII(R). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 4977 25. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-004-07 > Jan > 07 > Engine Controls - MIL ON/DTC P0480 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0480 Set NUMBER: 18-004-07 GROUP: Vehicle Performance DATE: January 24, 2007 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. SUBJECT: Flash: MIL DTC P0480-Cooling Fan 1 Control Circuit OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2005-2006 (RS) Caravan/Town & Country NOTE: This bulletin applies to vehicles equipped with a 3.3 or 3.8L engine (sales code EGA and EGH). SYMPTOM/CONDITION: Customer may experience MIL illumination. Lack of fan operation may be noted. This may occur when previous drive cycles occurred in heavy snow conditions causing snow and/or ice to form at the base of the fan shroud blocking the fan blade. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than P0480 are present record them on the repair order and repair as necessary before proceeding further with this bulletin. After performing the diagnostic procedures available in TechCONNEGT listed for P0480, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE USING DRBIII(R) AND DOWNLOADING THE FLASH FILE FROM DealerCONNECT > Tech TOOLS: NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-004-07 > Jan > 07 > Engine Controls - MIL ON/DTC P0480 Set > Page 4982 Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2007 Diagnostics". c. "All (Except Below)". d. "Engine". e. "Module Display". f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to the next step. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-004-07 > Jan > 07 > Engine Controls - MIL ON/DTC P0480 Set > Page 4983 13. Reset the "Pinion Factor" as necessary. 14. Perform the transmission Quick Learn Procedure as necessary. NOTE: The following step is required by law. 15. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4988 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4989 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4990 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4991 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4992 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4993 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4994 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4995 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4996 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4997 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4998 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4999 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5000 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5001 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5002 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5003 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5004 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5005 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5006 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls - MIL ON/DTC P0135 Set NUMBER: 18-010-05 REV. A GROUP: Vehicle Performance DATE: March 4, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-010-05, DATED FEBRUARY 17, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN UPDATED VEHICLE BUILD DATE. THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD APRIL, 2005. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DIG) P0135 - 02 Sensor 1/1 Heater Performance OVERVIEW: This bulletin involves verifying the proper 1/1 02 Sensor is installed on the vehicle and reprogramming the Powertrain Control Module with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager NOTE: **This bulletin applies to 2005 CS and RS vehicles equipped with a 3.8L engine (sales code EGH) built on and between July 8, 2004 (MDH 0708XX) and March 2, 2005 (MDH 0302XX). 2005 RS vehicles equipped with a 3.3L engine (sales code EGA, EGM and EGH) built on and between July 8, 2004 (MDH 0708XX) and October 29, 2004 (MDH 1029XX).** SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by the following Diagnostic Trouble Codes (DTC's): P0135 - 02 Sensor 1/1 Heater Performance DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than the one listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. Verify that the correct 02 Sensor is installed on the vehicle. Refer to Service Bulletin 08-008-05. Installing an incorrect 1/1 02 sensor will cause a MIL illumination for DTC P0135 - 02 Sensor 1/1 Heater Performance to be set. If the vehicle operator describes or experiences the Symptom/Condition and the correct 1/1 02 sensor is installed on the vehicle, perform the Repair Procedure. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 5011 SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-010-05A > Mar > 05 > Engine Controls - MIL ON/DTC P0135 Set > Page 5012 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls/Ignition - MIL ON/Misfire DTC's Set NUMBER: 18-018-04 GROUP: Vehicle Performance DATE: April 27, 2004 THE SOFTWARE IS AVAILABLE ON TechCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE SOFTWARE AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS CD/DVD JUNE, 2004. SUBJECT: Flash: MIL Illumination Diagnostic Trouble Codes (DTCs) P0300, P0301, P0302, P0303, P0304, P0305, P0306 OVERVIEW: This bulletin involves replacing the spark plugs, ignition wires and if necessary, reprogramming the Powertrain Control Module with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with a 3.3L engine (sales code EGA or EGM) or 3.8L engine (sales code EGH), built on or before April 2, 2004 (MDH 0402XX). SYMPTOM/CONDITION: The vehicle operator may experience a MIL illumination. Further diagnosis may determine that the MIL was caused by one or more of the following DTC's: ^ P0300-MULTIPLE CYLINDER MISFIRE ^ P0301-CYLINDER # 1 MISFIRE ^ P0302-CYLINDER # 2 MISFIRE ^ P0303-CYLINDER # 3 MISFIRE ^ P0304-CYLINDER # 4 MISFIRE ^ P0305-CYLINDER # 5 MISFIRE ^ P0306-CYLINDER # 6 MISFIRE DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with TechCONNECT and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform Repair Procedure 1 and if necessary, Repair Procedure 2. If an "Authorized Modification Label" is present and states that Service Bulletin 18-016-04 has been performed, it is not necessary to perform Repair Procedure 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 5017 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being preformed. REPAIR PROCEDURE 1: Replace spark plugs and ignition cables 1. Replace the spark plugs and ignition (spark plug) cables. Refer to the service information available in TechCONNECT or the Town & Country and Caravan service manual (publication no. 81-370-04062CD), page 8I-10. 2. If Service Bulletin 18-016-04 has not been performed, proceed to Repair Procedure 2. If Service Bulletin 18-016-04 has been performed, no further action is necessary. REPAIR PROCEDURE 2: Flash Reprogram PCM NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 5018 c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in Step # 2 in the "Parts Criteria" area and select 'Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to Step # 13. NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-018-04 > Apr > 04 > Engine Controls/Ignition - MIL ON/Misfire DTC's Set > Page 5019 13. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-04 > Apr > 04 > Engine Controls - Warm Engine Rough Idle PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Warm Engine Rough Idle NUMBER: 18-016-04 GROUP: Vehicle Performance DATE: April 13, 2004 THE SOFTWARE WILL BE AVAILABLE ON TechCONNECT APRIL 13, 2004. SUBJECT: Flash: Rough Idle When Engine Is At Normal Operating Temperature OVERVIEW: This bulletin involves selectively erasing and reprogramming the Powertrain Control Module (PCM) with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan/Voyager NOTE: This bulletin applies to vehicles equipped with a 3.3L or 3.8L engine (sales code EGA, EGH or EGM) built on or before April 2, 2004. SYMPTOM/CONDITION: The vehicle operator may describe a rough idle after the engine has warmed up to normal operating temperature. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R), must be programmed with the latest revision level available. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-04 > Apr > 04 > Engine Controls - Warm Engine Rough Idle > Page 5024 NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRB III(R) reboots to the MAIN MENU, proceed to (STEP # 2) 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the "PCM part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "PCM part # " recorded in (STEP # 2) in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate calibration. 5. Select the calibration. 6. Select the "DRBIII(R)" radio button which is next to the "Download/Update" button. 7. Select the "Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to (STEP # 9). 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood, install a battery charger and verify battery state is above 12.5 volts. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to (STEP # 13). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 18-016-04 > Apr > 04 > Engine Controls - Warm Engine Rough Idle > Page 5025 13. Type the necessary information on the "Authorized Modification Label p/n 04275086AB and attach near the VECI label (Fig. 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls Programming Generic PCMs NUMBER: 18-029-07 GROUP: Vehicle Performance DATE: April 26, 2007 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-006-04 REV. B, DATED SEPTEMBER 13, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A MINOR REVISION AND **ASTERISKS** HAVE BEEN USED TO HIGHLIGHT UPDATED PL PARTS APPLICATIONS. SUBJECT: Generic Powertrain Control Module (PCM) Procedure OVERVIEW: This bulletin involves programming a generic PCM with software. MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR) Ram Truck 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004-2005 (KJ) Liberty 2004 - 2005 (KJ) Cherokee (International Markets) 2002 - 2004 (LH) 300M/Concorde/Intrepid 2004-2005 (PL) Neon 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2005 (TJ) Wrangler Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 5031 NOTE: Refer to the table for specific applications. DISCUSSION: Mopar(R) is currently phasing out pre-programmed PCMs for the vehicles listed. New modules will no longer be pre-programmed when received from Mopar(R). Replacement of future PCMs will require programming utilizing the DRBIII(R) and TechCONNECT. The PCM will not operate the engine until it is programmed. A Diagnostic Trouble Code (DTC) will be set - "not programmed". CAUTION: Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The module can only be reprogrammed to a more recent version of that calibration. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 5032 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 5033 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 5034 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 5035 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 5036 PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: When flashing a 2002 - 2004 LH vehicle the BCM may need to be disconnected if experiencing failures during the flash of the transmission portion of the PCM. The BCM will need to be disconnected after the module ID portion of the flash is complete. Before pressing Page Forward to begin the flash of the PCM Turn the Key to the OFF position and disconnect the BCM. Then turn the KEY to the RUN position and Press Page Forward to begin the PCM flash session. NOTE: If vehicle is a DAKOTA, then the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for any erroneous DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU power up the DRBIII(R) and then: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRB III(R) reboots to the MAIN MENU, proceed to Step 2. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 5037 NOTE: If your vehicle is a 2002 LH and the original PCM part number begins with 04 the technician should use the 2002 LH Part Number Reference chart above to determine the corresponding "NEW" part number. This new number from the chart should then be entered into the Tech tools application as the original part number. If the original PCM number begins with 05 no change to the flash selection process is required. 2. With the ignition switch in the "RUN" position, determine the original part number of the PCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Module Display" f. Record the first ten (10) characters of the "PCM part # " on the repair order for later reference. NOTE: If the PCM is not operational, the part number can be obtained from the label on the old controller. If the label on the controller is not legible, proceed to next step. 3. Page back to the "Main Menu" 4. Determine if the vehicle is equipped with SKIM. Using the DRBIII(R) select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "System Monitor" e. "J1850 Module Scan" f. Look for "SKIM" in the list of modules. 5. If the vehicle is not equipped with SKIM then proceed to step 6. If the vehicle is equipped with SKIM obtain the vehicle Personal Identification Number (PIN) before continuing with step 6. This information is available from one of the following: a. The original selling invoice. b. The DealerCONNECT system under the "Sales" or "Parts" tabs - select "Key Codes". c. By contacting the DaimlerChrysler Customer Assistance Center (DCCAC) at 1-800-992-1997. CAUTION: Failure to install the SKIM pin number into the module after flashing the PCM will cause a start and stall condition. 6. Replace the PCM using the appropriate generic control module. Refer to the service information available in TechCONNECT or the appropriate service manual in Section 8E, Electronic Control Modules, Powertrain Control Module, Removal/Installation. 7. Open the hood, install a battery charger and verify battery state is above 11.5 volts. 8. If the old "PCM part # " is known, proceed to step 14. If the old "PCM part # " is not known, proceed to next step. 9. On DealerCONNECT select the "Service" tab. 10. Select "Vehicle Information Plus". 11. Manually enter the VIN and mileage and select "Enter". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 5038 12. Select the "Vehicle Option" tab. 13. Under the "Vehicle Option window, identify and record: a. Engine. b. Emissions (Federal or California). c. Transmission (Automatic, 5-speed manual, etc.). 14. Connect the DRBIII(R) to TechCONNECT and the vehicle. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 15. TechTOOLS should automatically populate the VIN in the "Vehicle Criteria area and the available updates. If not, manually enter the VIN then TechTOOLS will populate the available updates. NOTE: Do NOT enter the generic controller part number in step 16a below. 16. Determine the proper calibration: a. If the old "PCM part # " is known, enter the part number of the old controller in the "Parts Criteria p/n window. Proceed to step 16. b. If the old "PCM part # " is not known, select the correct calibration based on the information that was recorded from "Vehicle Options" in step 13. 17. Select the correct calibration. 18. Select the "Download/Update button. 19. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT/DRBIII(R). When the flash process is completed, proceed to next step. 20. Enter the VIN in the PCM. Using the DRBIII® select: a. "DRBIII Standalone" b. "1998 - 2004 Diagnostics" c. "All" d. "Engine" e. "Miscellaneous" f. "Check VIN" g. If the vehicle is not equipped with SKIM proceed to step 20h. If the vehicle is equipped with SKIM follow the directions on the DRBIII(R). When the VIN and SKIM key has been programmed, proceed to step 20. h. Enter the VIN as requested by the DRBIII(R). 21. Update the PCM mileage. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Check PCM Odometer" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 5039 g. "NO" h. Enter the current odometer mileage and then press "Enter". i. Cycle the ignition key to the OFF position and back to the ON position and then press "Enter". 22. Proceed as follows: a. If the vehicle is equipped with an automatic transmission, proceed to step 24. b. If the vehicle is equipped with a non-turbo engine and manual transmission, it is not necessary to set the pinion factor. Proceed to step 24. c. If the vehicle is equipped with a Turbo engine and manual transmission, proceed to step 23. 23. On vehicles equipped with a Turbo engine and manual transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII® Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Engine" e. "Miscellaneous" f. "Pinion Factor" g. Select the correct tire size and then select "Page Back" to exit. h. Proceed to step 24. 24. On vehicles equipped with an automatic transmission, set the Pinion Factor. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2004 Diagnostics" c. "All (Except Below)" d. "Transmission" e. "Transmission Module" f. "Miscellaneous" g. "Pinion Factor" h. Select the correct tire size and then select "Page Back" to exit. i. Enter "Quick Learn" and then follow the instructions on the DRBIII(R). NOTE: Due to the PCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. NOTE: The following step is required by law. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-029-07 > Apr > 07 > Engine Controls - Programming Generic PCMs > Page 5040 25. Type the necessary information on the "Authorized Modification Label" p/n 04275086AB and attach near the VECI label (Fig 1). POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Refer to Quick Labor Operations or the appropriate Labor Operation Time Schedule manual. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery Technical Service Bulletin # 18-037-05 Date: 051020 Engine Controls - Flash Programming Failure Recovery NUMBER: 18-037-05 GROUP: Vehicle Performance DATE: October 20, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Flash Programming Failure Recovery Using DRBIII(R) OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and information on recovery procedures for failed flash attempts. MODELS: 1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan 1995 - 2003 (AB) Ramvan/Wagon 1992 - 1994 (AJ) Lebaron Coupe/Convertible 1995 - 2004 (AN) Dakota 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1994 - 2002 (BRIBE) Ram Pickup 2004 - 2006 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2005 (DR/DH/D1) Ram Pickup 1995 - 2000 (FJ) Avenger/Sebring/Talon 1996 - 2000 (CS) Chrysler Voyager (International Markets) 1995 - 2000 (JA) Breeze/Cirrus/Stratus 2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible 2002 - 2005 (KJ) Liberty/Cherokee (International Markets) 1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 (PG) PT Cruiser (International Markets) 1997 - 2002 (PR) Prowler 2001 - 2005 (PT) PT Cruiser 2001 - 2006 (RG) Chrysler Voyager (International Markets) 2001 - 2006 (RS) Town & Country/Caravan/Voyager Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5045 1995 - 2002 (SR) Viper 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) 1999 - 2004 (WJ) Grand Cherokee 1997 - 2001 (XJ) Cherokee 1993 - 1995 (YJ) Wrangler 2003 - 2006 (ZB) Viper 1995 - 1998 (ZG) Grand Cherokee (International Markets) 2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster 1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer DISCUSSION: NOTE: Many of the reasons a flash reprogramming procedure may not complete are documented in this service bulletin, but if you are constantly having issues performing the flash reprogramming procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to SPX/Miller Special Tools for service. Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an interruption or failure while reprogramming, are recoverable; a recoverable module is not covered under the provisions of the warranty. This service bulletin covers items that may cause this condition, a process to restart the flash procedure, and miscellaneous information that will help prevent needless replacement of control modules. GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or RECALL. Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE REQUIRED as part of completing the Service Bulletin/Recall. When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there are other legal requirements with labeling issues that are included in those service bulletins. Other non-emission related modules, such as instrument clusters and Body Control Modules (BCMs) do not require labels. FLASH REPROGRAMMING SEQUENCE OF EVENTS The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer. Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere with the process. This document seeks to provide information to minimize problems associated with vehicle control module flash reprogramming. The description that follows is for most PCMs and some TCMs. Other modules use different initiation procedures. The process starts by selecting an update from the TechCONNECT Client or ISIS and then "loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done using part number supersedence. This verification occurs only if an update is required, available (on the TechCONNECT Client or ISIS) and has been selected for programming. ^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming session. ^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe Memory" location within the module. This memory location is not affected by flash memory erasure and reprogramming, which are to follow. ^ Once the part number is safely stored, the flash memory in the control module is erased. From this point forward any interruption in the flash process, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5046 will result in a Non-Responsive module (NR). A NR module is a module that is either partially erased or partially programmed. ^ After erasure, the actual reprogramming procedure starts, and the update software is programmed into the flash memory within the module. ^ When reprogramming is completed, the flash memory is verified through an internal process in the DRBIII(R) using a "Check Sum". This value is compared against another value that represents what should be in memory and when matched, verifies successful reprogramming. ^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The module exits the "Boot Strap" mode when the switch is turned off. ^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The DRBIII(R) then reads the new part number in flash memory (along with a new computer program the new part number is placed into the module's memory). If the new part number matches the expected part number, the flash reprogramming session has completed successfully. SOFTWARE VERSIONS MUST BE CURRENT Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you have the most current DRBIII(R) software installed. To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version. Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The installed DRBIII(R) software version can generally be found at the bottom center of most screens. Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and comparing it to what is available from a current TechCONNECT Client as described above. If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions installed. DO NOT PASS on the option for updating to a "minor" revision! Major updates require the DRBIII(R) to be updated prior to allowing any flash programming. DRBIII(R) CABLES A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft. Cable, DRBIII(R) to OBDII (J1962) DLC Connector. CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct cable has a RED connector, which plugs into the DRBIII(R). The cable modification enhances the DRBIII(R) communication capabilities when dealing with the flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC connector configurations. The new cable is required for ALL flash reprogramming sessions, and can be used wherever the previous CH700017001 cables were used. While not recommended for flash reprogramming usage, if you require a longer cable, there is also a 12-foot cable released under pin CH7001A The production of the previous CH700017001 cables has ceased. All orders placed will be superseded to part number CH7000A/CH7001A. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5047 NOTE: Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are damaged or do not lock securely, and all mating connections including checking for corrosion on the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash reprogramming. Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming sessions. The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O cable (Pre-OBDII MMC vehicles will use the CH7005 cable). TechCONNECT CABLE (GPIB) Replace any suspect GPIB cable. The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R). This cable is used by the TechCONNECT Client for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash session, you may have to reload the update file that you selected on the TechCONNECT Client. TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT APPLICATION. 1. Turn-on the power to the DRBIII(R) unit. 2. Select option 2 "Connect to TechCONNECT" and press Enter. 3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number CH7035B) to the DRBIII(R) unit. 4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol converter, (part number CHGPIB-B). 5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the rear panel of the client CPU. 6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will detect the device and install software for it. Please wait for 25-30 seconds to complete the installation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5048 ISIS NULL MODEM CABLE Replace any suspect null modem cables. International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes disconnected during a flash download session, you will have to reload the update file or files. GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS Consider ALL cables to be wear items. Many successful dealers have dedicated cables devoted to "Flash ONLY". Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available. Inspect vehicle diagnostic connectors for potential problems that might cause communication interruptions. There are now clip repair kits available through teamPSE to replace the retaining clips for two of these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above 25 lbs. of axial force. Kits are described in the table. It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general damage beyond the retaining clips. ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5049 These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT) was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users should closely follow the instructions that come with the tool. If the tool has not been initialized, there is a known condition where it may take up to 5 or more attempts for it to fully initialize and become functional. NOTE: Once it has successfully flashed, it is initialized and no further action is required. PREPARING TO FLASH It is highly recommended that a sign, or other process, be used that notifies other users that a FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash reprogramming sessions at critical junctures can render a module inoperative. Another user may not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do something on the vehicle that could interrupt the flash process. Before starting the flash session, read, record and erase all DTCs found on the vehicle. Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have been known to be swept off vehicle windshields by accident when a user bumps the wiper switch). Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash reprogramming errors may occur. VEHICLE BATTERY VOLTAGE The flash programming procedure puts a load on the electrical system that may last from five to twenty minutes depending on the particular flash reprogramming update. Connect a battery charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by voltage fluctuations. Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to ensure adequate and stable system voltages on the module being flash reprogrammed. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Connected/Disconnected Flash Mode Using TechCONNECT CONNECTED MODE FLASHING USING TechCONNECT NOTE: Capable but not recommended. In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most vehicles). This mode is useful when the TechCONNECT Client is next to the vehicle being flashed. Another advantage of this mode is that you are able to determine all available flash updates for the vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button. Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client while a flash update is in-progress. The reprogramming procedure of this mode is initiated by selecting the controller option and clicking "Download/Update" button on the TechCONNECT client. DISCONNECTED FLASH MODE NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5050 This is the preferred method. This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client. This is a popular mode for flashing in a remote area of the service garage or in a back lot. Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s). To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will be used to communicate with the TechCONNECT Client (for update file downloading) while the CH7025 cable is used to provide power to the DRBIII(R). After making the above connections, you are able to select one or more updates that you want to perform. These selections are made by highlighting the desired updates and then clicking on the "Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client. Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT Client screen) will change color from GREEN to RED. At this point you must de-select entries until the indicator changes color to GREEN again. When the updates have finished downloading, you may disconnect from the TechCONNECT Client and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R) memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for another 8 hours without power. To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery jump box". Pay Attention While Performing Flash Reprogram Procedures PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES Before downloading the flash files, double check to see if the files that you have selected are the appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files selected don't download on the first attempt, try again. The technician should NOT leave the vehicle when flash reprogramming a module. Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a stable surface. If you are using a battery charger, insure that the settings and charging times are correct and that the battery post clamps are securely fastened. Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part number from the module that is to be flash reprogrammed. Some control modules are not "abort-recovery" capable. When this is true, the scan tool will indicate so by displaying a WARNING message prior to the start of reprogramming. For these modules it is especially important that all precautions and procedures, outlined here, are carefully followed. Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or "Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to DRBIII(R) instructions. Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled prior to the start of reprogramming and re-installed immediately after completion. Be careful not to anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the many possible changes that occur with each new release of scan tool software, always allow the TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming. Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not completed within 25 minutes after starting a flash reprogramming update, an error has most likely occurred (Record the message that appears on the screen when a failure occurs). If this is the case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power up) before attempting to restart the flash process. If the module still won't respond, turn the ignition key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the ignition key to run and try to restart the flash process again. Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were followed, perform the following: ^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R). (Push MORE and YES buttons at the same time, then press F4). ^ Reload the flash update file from the TechCONNECT Client. ^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5051 ^ Proceed to reflash the module. On vehicles that have multiple flash updates available, always complete and verify each flash update before attempting the next one. After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle. A variety of DTCs may be set, which are usually related to a loss of communication with the module(s) being reprogrammed. Verify the update by reading the new part number using the DRBIII(R). A good double check is to read the part number using DRBIII(R) stand alone. At times, other modules, wired in parallel, to the DLC connector have prevented flash reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules that were disconnected. Refer to the "Programmable Modules" section later in this document for more information. Error Messages ERROR MESSAGES Block Echo/Compare Errors Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables (CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector. Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable recommendations. Checksum Errors Checksum Errors are generally caused by corrupt flash update files, which can be caused by DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press "F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to the DRBIII(R). Then re-attempt the flash reprogramming process. Enhanced and Original Abort Recovery ENHANCED ABORT RECOVERY Interruptions in the flash process are one of the main reasons for failed flash sessions and non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will leave the control module in a non-functional state. Generally, but not always, NR modules may be recovered successfully. Briefly, abort recovery is the process used to get a NR module back to a fully functional state with the latest software update. The technician should be familiar with the other sections in this document and follow all DRBIII(R) user prompts carefully. There are two methods for abort-recovery. The newer method is called "Enhanced Abort Recovery". This is the preferred method since the original method takes several minutes longer and requires the correct selection of module type from a list of possible PCM's or TCM's. Starting with Release 60.1, a new useful feature was added to the flash reprogramming application for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type information to a "Safe Memory" location. This method allows for rapid recovery of the module part number and minimizes errors that could otherwise be made by selecting the wrong controller type. It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash reprogramming you must erase the saved recovery information in order to successfully perform flash reprogramming. Be careful to match the YME information displayed on the enhanced abort recovery screen with the vehicle and module that you are attempting to recover. If you use the recovery file on a different vehicle and module you could damage the module. The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if you previously encountered a problem that prevented a flash session from completing normally. If your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that the flash application will not show any recovery information at the start of your next flash session. Enhanced abort recovery features: ^ Reduces the amount of time for the Module ID process. ^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and Controller Type. ^ Currently only applicable to Engine and Transmission flash reprogramming. ^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the user. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5052 ^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be reloaded. ^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the original method of abort recovery. ^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller into bootstrap (reprogramming) mode. ORIGINAL ABORT RECOVERY If the choice is made to use the original method of abort recovery, a NR module is not always able to provide the DRBIII with ID information. In this case the technician must enter this when prompted by the DRBIII(R). Be patient when performing this process. If the module does not respond to standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not determine engine controller type. Please select from list" along with a list of possible controller types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of "engine" and list the possible trans controller types). Because of module variations, it is important to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do this will cause further problems and may damage the module. Tables are provided below to help identify the proper module type to select. These tables correctly identify the modules that were on the vehicles when they were built. However, some vehicles will have module types which were superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting flash reprogramming. NOTE: When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to the OFF position. The key must be rotated to the point at which it can be removed from the ignition switch. On most vehicles the switch is on the steering column and at this position the steering column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the key past this position which may engage the starter motor. This creates electrical noise which interferes with the flash process. General Steps for Abort Recovery 1. Review all Tips and Techniques before continuing. Pay special attention to the section on Preparing to Flash a controller and to the Programmable Modules section. 2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position. 3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and then reconnecting the cable. 4. Depending on where the flash session was aborted, the DRBIII(R) may require that the technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM configuration table below as a guide. This step is not necessary if using the enhanced abort recovery method. 5. After selecting the proper control module type or choosing enhanced abort recovery, follow the prompts that are displayed on the DRBIII(R). NOTE: If an error message is displayed at this point, an incorrect module type was most likely selected. If this occurs, start the process over. 6. If the recovery process is unsuccessful, perform the following: a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this document. b. Reboot/Restart the TechCONNECT Client. c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same time, then press F4). d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to be reloaded from the TechCONNECT Client or ISIS DVD. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5053 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5054 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5055 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5056 Programmable Modules The following pages list the various modules that have flash reprogramming capability. It does not mean that a flash is currently available. What will be described are the module types and variations, followed by items to note, and finally, abort recovery specifics if applicable. Powertrain Modules - Engine and Transmission ENGINE - POWERTRAIN CONTROL MODULE (PCM) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5057 There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the module information and module type using your DRBII I®. PCM information is used by many modules. Be sure to check DIG's before and after performing all flash reprogramming event. The DTC's associated with flash reprogramming generally relate to "lack of communication" with the other modules during the reprogramming session. SBEC Types: SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B NOTE: During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON, reconnect fuse or harness connection. Abort Recovery Specifics: ^ Follow instructions on the DRBIII® for the module type. See table above. ^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly identify a key cycle. In this case a Modified Key Cycle routine is required. This state is present when the following message is displayed on the DRBIII(R): "Can not read Part Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the RUN position, replace the battery supply fuse(s) instead. JTEC Types: ^ JTEC, JTEC+ NOTE: Viper ALL - Roll down windows especially Coupes before attempting a flash. NOTE: 1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after the PCM flash reprogramming session. Also see Transmission. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NGC Types: ^ NGC 1, NGC 2, and NGC 3 NOTE: There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC modules use one of the longest time spans for flash reprogramming (approximately 15 minutes). The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in a common package. The NGC2 controller incorporates the engine controller and an Electronic Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3 connectors may be populated with pins. NOTE: On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete turn the ignition switch to the OFF position, connect the CAB module connector, and then check for DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module connector was not disconnected, then the PCM may be recovered by following the procedure in this NOTE. Abort Recovery Specifics: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5058 ^ Follow DRBIII(R) prompts carefully. ^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the flash. CUMMINS Types: ^ CM551 and CM84x series NOTE: Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s) are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds. SIEMENS Types: ^ SIM-70 NOTE: The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery Specifics: Follow DRBIII(R) prompts carefully. BOSCH Types: ^ EDC15V, EDC15-C5, and EDC16 NOTE: While there have been other Bosch modules, the EDC15V is not flash reprogrammable. Transmission controllers are usually flashed on the vehicle (since 1996). Technicians may set the pinion factor on "NEW" modules either before or after flash reprogramming. Suggestions follow. After flash reprogramming and before returning the vehicle to the customer, always perform a "QuickLearn" to the TCM. EATX Types: ^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A NOTE: Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a service bulletin. Abort Recovery Specifics: ^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is completed during PIN verification. This DOES NOT mean the flash failed. Check for the part number using DRBIII(R) in standalone mode. This exists only for the service replacement modules listed above. Flash reprogramming for OE modules flash and read the part number correctly. Follow DRBIII(R) prompts carefully. NGC Types: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5059 ^ NGC1, NGC2, NGC3 NOTE: The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not. Vehicles with automatic transmissions using NGC2 will use an EATX4A. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the CAB controller may need to be disconnected when attempting to flash the NGC controller. (This should only be performed if an error occurs at the very beginning of the TCM flash portion.) SIEMENS Types: ^ EG552 NOTE: EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel engine (BUX), ZH Crossfire and VA Sprinter. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. JTEC Types: ^ JTEC,JTEC+ NOTE: Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are used on some Cummins equipped Dodge trucks with manual and automatic transmissions. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PRE 1996 EATX TRANSMISSION CONTROL MODULES Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD communications. For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those modules to the DRBIII(R) vehicle connector. For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new" (superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these updated modules. Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124. The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin 18-24-95. Types: ^ TCCM NOTE: These modules are found on AN, DN, and DR trucks. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5060 NON-POWERTRAIN CONTROL MODULES BODY CONTROL MODULE (BCM) Types: ^ BCM NOTE: Body control modules are found on passenger vehicles. NOTE: The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release software version 52.25 ^ 2001 LH - there is NO abort recovery available for the BCM. CENTRAL TIMER MODULE (CTM) Types: ^ CTM NOTE: CTMs are found on: AB, AN, DN, BR, and BE trucks. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. ELECTRONIC VEHICLE INFORMATION CENTER (EVIC) Types: ^ EVIC NOTE: 02-03 LH & WJ, and 03-04 KJ Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. FRONT CONTROL MODULE (FCM) Types: ^ FCM NOTE: Front control modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. INTEGRATED POWER MODULE (IPM) Types: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5061 ^ 1PM NOTE: Integrated power modules are found on CS, DR, RG, and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. POWER LIFT GATE (PLG) Types: ^ PLC NOTE: Power liftgate modules are found on CS and RS. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM) Types: ^ PSDM NOTE: Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM) Types: ^ DSDM NOTE: Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. NOTE: When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module. DRIVER DOOR MODULE (DDM) Types: ^ DDM NOTE: Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM) Types: ^ PDM NOTE: Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5062 Types: ^ MICs, eMICs NOTE: MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key and pull a specific fuse. ^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and is explained in the user prompts displayed during abort-recovery. Take the time to read and understand the instructions before proceeding. ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM) Types: ^ ARKEM NOTE: Arkem modules are found on PL and PT vehicles. There are up to and after modules. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. CLIMATE CONTROL (ATC, HVAC) Types: ^ HVAC, ATC, MTC NOTE: Generally, reprogramming for these modules is done using the standalone application rather than the Vehicle Flash application. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. ADJUSTABLE PEDAL MODULE (APM) Types: ^ APM NOTE: Found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. RAIN SENSOR MODULE (RSM) Types: ^ RSM NOTE:RSM modules are found on CS, RS, and WJ vehicles. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 5063 INTRUSION TRANSCEIVER MODULE (ITM) Types: ^ ITM ^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the TSB for important instructions. NOTE: ITM modules are found on WJ (BUX) and KJ (BUX) vehicles. Abort Recovery Specifics: ^ Follow DRBIII® prompts carefully. SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC. Types: ^ SRS, ORC NOTE: While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to support flash updates. Abort Recovery Specifics: ^ Follow DRBIII(R) prompts carefully. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation Pressure Regulating Solenoid: Description and Operation SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION The Solenoid/Pressure Switch Assembly (Fig. 276) is external to the transaxle and mounted to the transaxle case. The assembly consists of four solenoids that control hydraulic pressure to the LR/CC, 2/4, OD, and UD friction elements. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the PCM/TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The PCM/TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which by design allow fluid to pass through in their relaxed or "off" state. This allows transaxle limp-in (P, R, N, 2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the PCM/TCM during this test. It no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The PCM/TCM relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the PCM/TCM detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the PCM/TCM for the correct states (open or closed) in each gear as shown in the following chart: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 5070 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the PCM/TCM senses any switch open or closed at the wrong time in a given gear. The PCM/TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the PCM/TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 5071 Pressure Regulating Solenoid: Service and Repair SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect solenoid/pressure switch assembly connector (Fig. 277). 4. Disconnect input speed sensor connector (Fig. 277). 5. Remove input speed sensor (Fig. 278). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 5072 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 279). 7. Remove solenoid/pressure switch assembly and gasket (Fig. 280). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 280). 2. Install and torque three (3) bolts (Fig. 279) to 13 Nm (110 inch lbs.). 3. Install input speed sensor (Fig. 278) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector (Fig. 277). 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 inch lbs.) (Fig. 277). 6. Install air cleaner assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5076 Steering Column Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5077 Brake Transmission shift Interlock Solenoid Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5078 Shift Interlock Solenoid: Service and Repair SHIFT INTERLOCK SOLENOID REMOVAL 1. Disconnect battery negative cable. 2. Remove instrument panel lower shroud (Fig. 268). 3. Remove knee bolster (Fig. 269). 4. Remove steering column lower shroud. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5079 5. Disconnect Brake/Transmission Shift Interlock (BTSI) solenoid connector (Fig. 270). 6. Remove two (2) solenoid-to-column screws (Fig. 271). 7. Remove solenoid. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5080 1. Place interlock solenoid into position ensuring hook on end of solenoid plunger engages gearshift lever pawl pin. Install and tighten screws (Fig. 272). 2. Verify gearshift lever is in PARK (P) and connect solenoid connector (Fig. 273). 3. Install steering column lower shroud. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5081 4. Install knee bolster (Fig. 274). 5. Install instrument panel lower silencer (Fig. 275). 6. Connect battery negative cable. 7. Verify proper shift interlock system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications 41TE - Automatic Transaxle SOLENOID/PRESSURE SWITCH ASSY Bolt, Solenoid/Pressure Switch Assy. Connector .............................................................................................................................. 12 Nm (110 inch lbs.) Screw, Solenoid/Pressure Switch Assy. Connector ............................................................................................................................... 4 Nm (35 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5085 Shift Solenoid: Locations Transmission Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5086 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5087 Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5088 Transmission Solenodi/pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5089 Shift Solenoid: Description and Operation 41TE - Automatic Transaxle SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION The Solenoid/Pressure Switch Assembly (Fig. 313) is external to the transaxle and mounted to the transaxle case. The assembly consists of four solenoids that control hydraulic pressure to the LR/CC, 2/4, OD, and UD friction elements. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which by design allow fluid to pass through in their relaxed or "off" state. This allows transaxle limp-in (P, R, N, 2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. It no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11 - 23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following chart: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5090 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5091 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5092 Shift Solenoid: Service and Repair 41TE - Automatic Transaxle SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect solenoid/pressure switch assembly connector. 4. Disconnect input speed sensor connector. 5. Remove input speed sensor (Fig. 314). 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 315). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5093 7. Remove solenoid/pressure switch assembly and gasket (Fig. 316). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 316). 2. Install and torque three (3) bolts (Fig. 315) to 13 Nm (110 inch lbs.). 3. Install input speed sensor (Fig. 314) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector. 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 inch lbs.). 6. Install air cleaner assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation Pressure Regulating Solenoid: Description and Operation SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION The Solenoid/Pressure Switch Assembly (Fig. 276) is external to the transaxle and mounted to the transaxle case. The assembly consists of four solenoids that control hydraulic pressure to the LR/CC, 2/4, OD, and UD friction elements. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the PCM/TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The PCM/TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which by design allow fluid to pass through in their relaxed or "off" state. This allows transaxle limp-in (P, R, N, 2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the PCM/TCM during this test. It no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The PCM/TCM relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the PCM/TCM detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the PCM/TCM for the correct states (open or closed) in each gear as shown in the following chart: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 5099 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the PCM/TCM senses any switch open or closed at the wrong time in a given gear. The PCM/TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the PCM/TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 5100 Pressure Regulating Solenoid: Service and Repair SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect solenoid/pressure switch assembly connector (Fig. 277). 4. Disconnect input speed sensor connector (Fig. 277). 5. Remove input speed sensor (Fig. 278). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 5101 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 279). 7. Remove solenoid/pressure switch assembly and gasket (Fig. 280). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 280). 2. Install and torque three (3) bolts (Fig. 279) to 13 Nm (110 inch lbs.). 3. Install input speed sensor (Fig. 278) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector (Fig. 277). 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 inch lbs.) (Fig. 277). 6. Install air cleaner assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5105 Steering Column Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5106 Brake Transmission shift Interlock Solenoid Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5107 Shift Interlock Solenoid: Service and Repair SHIFT INTERLOCK SOLENOID REMOVAL 1. Disconnect battery negative cable. 2. Remove instrument panel lower shroud (Fig. 268). 3. Remove knee bolster (Fig. 269). 4. Remove steering column lower shroud. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5108 5. Disconnect Brake/Transmission Shift Interlock (BTSI) solenoid connector (Fig. 270). 6. Remove two (2) solenoid-to-column screws (Fig. 271). 7. Remove solenoid. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5109 1. Place interlock solenoid into position ensuring hook on end of solenoid plunger engages gearshift lever pawl pin. Install and tighten screws (Fig. 272). 2. Verify gearshift lever is in PARK (P) and connect solenoid connector (Fig. 273). 3. Install steering column lower shroud. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5110 4. Install knee bolster (Fig. 274). 5. Install instrument panel lower silencer (Fig. 275). 6. Connect battery negative cable. 7. Verify proper shift interlock system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications 41TE - Automatic Transaxle SOLENOID/PRESSURE SWITCH ASSY Bolt, Solenoid/Pressure Switch Assy. Connector .............................................................................................................................. 12 Nm (110 inch lbs.) Screw, Solenoid/Pressure Switch Assy. Connector ............................................................................................................................... 4 Nm (35 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5114 Shift Solenoid: Locations Transmission Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5115 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5116 Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5117 Transmission Solenodi/pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5118 Shift Solenoid: Description and Operation 41TE - Automatic Transaxle SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION The Solenoid/Pressure Switch Assembly (Fig. 313) is external to the transaxle and mounted to the transaxle case. The assembly consists of four solenoids that control hydraulic pressure to the LR/CC, 2/4, OD, and UD friction elements. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which by design allow fluid to pass through in their relaxed or "off" state. This allows transaxle limp-in (P, R, N, 2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. It no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11 - 23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following chart: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5119 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5120 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5121 Shift Solenoid: Service and Repair 41TE - Automatic Transaxle SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect solenoid/pressure switch assembly connector. 4. Disconnect input speed sensor connector. 5. Remove input speed sensor (Fig. 314). 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 315). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5122 7. Remove solenoid/pressure switch assembly and gasket (Fig. 316). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 316). 2. Install and torque three (3) bolts (Fig. 315) to 13 Nm (110 inch lbs.). 3. Install input speed sensor (Fig. 314) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector. 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 inch lbs.). 6. Install air cleaner assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Accumulator: Description and Operation 41TE Automatic Transmission ACCUMULATOR DESCRIPTION The 4XTE underdrive, overdrive, low/reverse, and 2/4 clutch hydraulic circuits each contain an accumulator. An accumulator typically consists of a piston, return spring(s), and a cover or plug. The overdrive and underdrive accumulators are located within the transaxle case, and are retained by the valve body (Fig. 145). The low reverse accumulator (Fig. 146) is also located within the transaxle case, but the assembly is retained by a cover and a snap-ring. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5127 The 2/4 accumulator is located in the valve body. It is retained by a cover and retaining screws (Fig. 147). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5128 Accumulator: Description and Operation 40TE Automatic Transaxle ACCUMULATOR DESCRIPTION The 4XTE underdrive, overdrive, low/reverse, and 2/4 clutch hydraulic circuits each contain an accumulator. An accumulator typically consists of a piston, return spring(s), and a cover or plug. The overdrive and underdrive accumulators are located within the transaxle case, and are retained by the valve body (Fig. 164). The low reverse accumulator (Fig. 165) is also located within the transaxle case, but the assembly is retained by a cover and a snap-ring. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5129 The 2/4 accumulator is located in the valve body. It is retained by a cover and retaining screws (Fig. 166). OPERATION The function of an accumulator is to cushion the application of a frictional clutch element. When pressurized fluid is applied to a clutch circuit, the application force is dampened by fluid collecting in the respective accumulator chamber against the piston and spring(s). The intended result is a smooth, firm clutch application. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications Clutch: Specifications Screw, L/R Clutch ................................................................................................................................ ................................................. 5 Nm (45 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Clutch: Description and Operation 41TE Automatic Transmission Driving Clutches 41TE - Automatic Transaxle DRIVING CLUTCHES - DESCRIPTION Three hydraulically applied input clutches are used to drive planetary components. The underdrive, overdrive, and reverse clutches are considered input clutches and are contained within the input clutch assembly (Fig. 173). The input clutch assembly also contains: - Input shaft - Input hub - Clutch retainer - Underdrive piston - Overdrive/reverse piston - Overdrive hub - Underdrive hub OPERATION The three input clutches are responsible for driving different components of the planetary geartrain. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5135 ELEMENTS IN USE AT EACH POSITION OF SELECTOR LEVER NOTE: Refer to the "Elements In Use" chart in Diagnosis and Testing for a collective view of which clutch elements are applied at each position of the selector lever. UNDERDRIVE CLUTCH The underdrive clutch is hydraulically applied in first, second, and third (direct) gears by pressurized fluid against the underdrive piston. When the underdrive clutch is applied, the underdrive hub drives the rear sun gear. OVERDRIVE CLUTCH The overdrive clutch is hydraulically applied in third (direct) and overdrive gears by pressurized fluid against the overdrive/reverse piston. When the overdrive clutch is applied, the overdrive hub drives the front planet carrier. REVERSE CLUTCH The reverse clutch is hydraulically applied in reverse gear only by pressurized fluid against the overdrive/reverse piston. When the reverse clutch is applied, the front sun gear assembly is driven. Holding Clutches 41TE - Automatic Transaxle DRIVING CLUTCHES - DESCRIPTION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5136 Two hydraulically applied multi-disc clutches are used to hold planetary geartrain components stationary while the input clutches drive others. The 2/4 and Low/Reverse clutches are considered holding clutches and are contained at the rear of the transaxle case. (Fig. 225). OPERATION ELEMENTS IN USE AT EACH POSITION OF SELECTOR LEVER NOTE: Refer to the "Elements In Use" chart in Diagnosis and Testing for a collective view of which clutch elements are applied at each position of the selector lever. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5137 2/4 CLUTCH The 2/4 clutch is hydraulically applied in second and fourth gears by pressurized fluid against the 2/4 clutch piston. When the 2/4 clutch is applied, the front sun gear assembly is held or grounded to the transaxle case. LOW/REVERSE CLUTCH The Low/Reverse clutch is hydraulically applied in park, reverse, neutral, and first gears by pressurized fluid against the Low/Reverse clutch piston. When the Low/Reverse clutch is applied, the front planet carrier/rear annulus assembly is held or grounded to the transaxle case. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5138 Clutch: Description and Operation 40TE Automatic Transaxle Driving Clutches DRIVING CLUTCHES DESCRIPTION Three hydraulically applied input clutches are used to drive planetary components. The underdrive, overdrive, and reverse clutches are considered input clutches and are contained within the input clutch assembly (Fig. 167). The input clutch assembly also contains: ^ Input shaft ^ Input hub ^ Clutch retainer ^ Underdrive piston ^ Overdrive/reverse piston ^ Overdrive hub ^ Underdrive hub OPERATION The three input clutches are responsible for driving different components of the planetary geartrain. NOTE: Refer to the "Elements In Use" chart in Diagnosis and Testing for a collective view of which clutch elements are applied at each position of the selector lever. UNDERDRIVE CLUTCH The underdrive clutch is hydraulically applied in first, second, and third (direct) gears by pressurized fluid against the underdrive piston. When the underdrive clutch is applied, the underdrive hub drives the rear sun gear. OVERDRIVE CLUTCH The overdrive clutch is hydraulically applied in third (direct) and overdrive gears by pressurized fluid against the overdrive/reverse piston. When the overdrive clutch is applied, the overdrive hub drives the front planet carrier. REVERSE CLUTCH The reverse clutch is hydraulically applied in reverse gear only by pressurized fluid against the overdrive/reverse piston. When the reverse clutch is applied, the front sun gear assembly is driven. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5139 Holding Clutches HOLDING CLUTCHES DESCRIPTION Two hydraulically applied multi-disc clutches are used to hold planetary geartrain components stationary while the input clutches drive others. The 2/4 and Low/Reverse clutches are considered holding clutches and are contained at the rear of the transaxle case. (Fig. 196). OPERATION NOTE: Refer to the "Elements In Use" chart in Diagnosis and Testing for a collective view of which clutch elements are applied at each position of the selector lever. 2/4 CLUTCH The 2/4 clutch is hydraulically applied in second and fourth gears by pressurized fluid against the 2/4 clutch piston. When the 2/4 clutch is applied, the front sun gear assembly is held or grounded to the transaxle case. LOW/REVERSE CLUTCH The Low/Reverse clutch is hydraulically applied in park, reverse, neutral, and first gears by pressurized fluid against the Low/Reverse clutch piston. When the Low/Reverse clutch is applied, the front planet carrier/rear annulus assembly is held or grounded to the transaxle case. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly Clutch: Service and Repair Disassembly 41TE - Automatic Transaxle Input Clutch Assembly DISASSEMBLY 1. Mount input clutch assembly to Input Clutch Pressure Fixture (Tool 8391). 2. Tap down reverse clutch reaction plate to release pressure from snap ring (Fig. 226). 3. Remove reverse clutch snap ring (Fig. 227). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5142 4. Pry up and remove reverse clutch reaction plate (Fig. 228) (Fig. 229). 5. Remove the reverse clutch pack (two frictions/ one steel) (Fig. 230). NOTE: Tag reverse clutch pack for reassembly identification. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5143 6. Remove the OD/Reverse pressure plate snap ring (Fig. 231). 7. Remove OD/Reverse pressure plate (Fig. 232). 8. Remove OD/Reverse pressure plate wave snap ring (Fig. 233). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5144 9. Remove OD shaft/hub and OD clutch pack (Fig. 234) (Fig. 235). NOTE: Tag overdrive clutch pack for reassembly identification. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5145 10. Remove and inspect #3 & #4 thrust washers (Fig. 236). 11. Remove the underdrive shaft assembly (Fig. 237). 12. Remove the #2 needle bearing (Fig. 238). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5146 13. Remove the OD/UD reaction plate tapered snap ring (Fig. 239). NOTE: The OD/UD clutch reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up. 14. Remove the OD/UD reaction plate (Fig. 240). 15. Remove the first UD clutch disc (Fig. 241). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5147 16. Remove the UD clutch flat snap ring (Fig. 242). NOTE: Tag underdrive clutch pack for reassembly identification. 17. Remove the UD clutch pack (Fig. 243). CAUTION: Compress return spring just enough to remove or install snap ring. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5148 18. Using Tool 5059A and an arbor press, compress UD clutch piston enough to remove snap ring (Fig. 244) (Fig. 245). 19. Remove spring retainer (Fig. 245). 20. Remove UD clutch piston (Fig. 246). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5149 21. Remove input hub tapered snap ring (Fig. 247). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5150 22. Tap on input hub with soft faced hammer and separate input hub from OD/Reverse piston and clutch retainer (Fig. 248) (Fig. 249). 23. Separate clutch retainer from OD/Reverse piston (Fig. 250). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5151 24. Using Tool 6057 and an arbor press, compress return OD/Reverse piston return spring just enough to remove snap ring (Fig. 251) (Fig. 252). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5152 25. Remove input shaft to input clutch hub snap ring (Fig. 253). 26. Using a suitably sized socket and an arbor press, remove input shaft from input shaft hub (Fig. 254). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5153 Clutch: Service and Repair Assembly 41TE - Automatic Transaxle Input Clutch Assembly ASSEMBLY Use petrolatum on all seals to ease assembly of components. 1. Using an arbor press, install input shaft to input shaft hub (Fig. 255). 2. Install input shaft snap ring (Fig. 256). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5154 3. Using an arbor press and Tool 6057, Install OD/Reverse piston return spring and snap ring (Fig. 257) (Fig. 258). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5155 4. Install the OD/Reverse piston assembly to the input clutch retainer as shown in (Fig. 259). 5. Install the input hub/shaft Assy. to the OD/Reverse piston/clutch retainer Assy. (Fig. 260). 6. Install input hub tapered snap ring (Fig. 261). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5156 7. Install UD clutch piston (Fig. 262). 8. Install UD piston return spring and Tool 5067 as shown in (Fig. 263). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5157 9. Using Tool 5059A and an arbor press, Install the UD spring retainer and snap ring. (Fig. 264) (Fig. 265) Compress just enough to install snap ring. CAUTION: Compress return spring just enough to install snap ring. 10. Install the UD clutch pack. Leave out upper disc, until snap ring is installed (Fig. 266). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5158 11. Install the UD clutch flat snap ring (Fig. 267). 12. Install the last UD clutch disc (Fig. 268). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5159 13. Install the OD/UD clutch reaction plate and snap ring (Fig. 269) (Fig. 270). The OD/UD clutches reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up. NOTE: Snap ring ends must be located within one finger of the input clutch hub. Be sure that snap ring is fully seated, by pushing with screwdriver, into snap ring groove all the way around. 14. Seat tapered snap ring to ensure proper installation (Fig. 271). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5160 15. Install input clutch assembly to the Input Clutch Pressure Fixture-Tool 8391 (Fig. 272). 16. Set up dial indicator on the UD clutch pack as shown in (Fig. 273). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5161 17. Using moderate pressure, press down and hold (near indicator) the UD clutch pack with screwdriver or suitable tool and zero dial indicator (Fig. 274). When releasing pressure on clutch pack, indicator reading should advance 0.005 - 0.010. CAUTION: Do not apply more than 30 psi (206 kPa) to the underdrive clutch pack. 18. Apply 30 psi (206 kPa) to the underdrive hose on Tool 8391 and measure UD clutch clearance. Measure and record UD clutch pack measurement in four (4) places, 90° apart. 19. Take average of four measurements and compare with UD clutch pack clearance specification. Underdrive clutch pack clearance must be 0.94 - 1.50 mm (0.037 - 0.059 inch). 20. If necessary, select the proper reaction plate to achieve specifications: 21. Install the OD clutch pack (four frictions/three steels) (Fig. 275). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5162 22. Install OD pressure plate waved snap ring (Fig. 276). 23. Install the OD/Reverse pressure plate with large step down (towards OD clutch pack) (Fig. 277). 24. Install OD pressure plate flat snap ring (Fig. 278). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5163 25. Measure OD clutch pack clearance. Set up dial indicator on top of the OD/Reverse pressure plate as shown in (Fig. 279). 26. Zero dial indicator and apply 30 psi (206 kPa) air pressure to the overdrive clutch hose on Tool 8391. Measure and record OD clutch pack measurement in four (4) places, 90° apart. 27. Take average of four measurements and compare with OD clutch pack clearance specification. The Overdrive (OD) clutch pack clearance is 1.07 - 3.25 mm (0.042 - 0.128 inch). If not within specifications, the clutch is not assembled properly. There is no adjustment for the OD clutch clearance. 28. Install reverse clutch pack (two frictions/one steel) (Fig. 280). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5164 29. Install reverse clutch reaction plate with the flat side down towards reverse clutch (Fig. 281). 30. Tap reaction plate down to allow installation of the reverse clutch snap ring. Install reverse clutch snap ring (Fig. 282). 31. Pry up reverse reaction plate to seat against snap ring (Fig. 283). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5165 32. Set up a dial indicator on the reverse clutch pack as shown in (Fig. 284). 33. Using moderate pressure, press down and hold (near indicator) reverse clutch disc with screwdriver or suitable tool and zero dial indicator (Fig. 285). When releasing pressure, indicator should advance 0.005 - 0.010 as clutch pack relaxes. 34. Apply 30 psi (206 kPa) air pressure to the reverse clutch hose on Tool 8391. Measure and record reverse clutch pack measurement in four (4) places, 90° apart. 35. Take average of four measurements and compare with reverse clutch pack clearance specification. The reverse clutch pack clearance is 0.89 - 1.37 mm (0.035 - 0.054 inch). Select the proper reverse clutch snap ring to achieve specifications. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5166 36. To complete the assembly, reverse clutch and overdrive clutch must be removed. 37. Install the #2 needle bearing (Fig. 286). 38. Install the underdrive shaft assembly (Fig. 287). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Disassembly > Page 5167 39. Install the #3 thrust washer to the underdrive shaft assembly. Be sure five tabs are seated properly (Fig. 288). 40. Install the #3 thrust plate to the bottom of the overdrive shaft assembly. Retain with petrolatum or transmission assembly gel (Fig. 289). 41. Install the overdrive shaft assembly (Fig. 290). 42. Reinstall overdrive and reverse clutch as shown. Rechecking these clutch clearances is not necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations Control Module: Locations Control Module Locations NGC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 5171 Control Module: Description and Operation Fig.14 Transmission Control Module (TCM) Location The Transmission Control Module (TCM) is located behind the left fender and is fastened with three screws to three clips in the left frame rail forward of the suspension (Fig. 14). The TCM is the controlling unit for all electronic operations of the transaxle. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transaxle. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the J1850 communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor (CKP) - Transmission Range Sensor (TRS) - Pressure Switches (L/R, 2/4, OD) - Transmission Temperature Sensor (Integral to TRS) - Input Shaft Speed Sensor - Output Shaft Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Speed Control ON/OFF Switch - Engine Coolant Temperature - Ambient/Battery Temperature - Brake Switch Status - DRB Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids (LR/CC, 2/4, OD and UD) - Vehicle Speed (to PCM) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 5172 - Torque Reduction Request (to PCM) An example of a TCM indirect output is: - Transmission Temperature (to PCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indices (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB scan tool) Clutch Volume Index (CVI) An important function of the TCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.15 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transaxle gear ratio. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 15). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 5173 Clutch Volumes Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 5174 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Locations > Page 5175 Control Module: Service and Repair ELECTRONIC PINION FACTOR (IF APPLICABLE) NOTE: After replacing the EATX/PCM, you must reprogram pinion factor. In some vehicle applications, the pinion factor is a fixed value and cannot be changed or updated. The transmission output speed signal supplies distance pulses to the control module, which are used to calculate speed and mileage. A pinion factor is stored in the control module in order to provide the appropriate distance pulses for other vehicle systems. The pinion factor is programmed into the control module at the assembly plant. The pinion factor must be set when replacing the control module. If the pinion factor is not set or incorrectly set, any speed related functions will not operate correctly i.e. speedometer, speed control, rolling door locks, other control modules will be affected that depend on speed information. Using the following steps, the pinion factor can be checked and/or reset using the DRBIII: 1. Select Transmission system, then Miscellaneous functions, then Pinion Factor. The DRBIII will display the current tire size. 2. If the tire size is incorrect, press the Enter key and then select the correct size. 3. Press the Page Back key to exit the reset procedure. Notes About Electronic Pinion Factor Features The nature of the electronic pinion factor requires that certain features must be taken into consideration. ^ If no pinion factor is stored in an installed control module, the vehicle speedometer will not operate, engine speed will be limited to 2300 RPM, and catalyst damage may occur. ^ Selecting a wrong tire size will cause the speedometer to be inaccurate and will also cause any speed related features to operate improperly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5181 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Specifications > Capacity Specifications Differential Fluid - A/T: Capacity Specifications Automatic Transaxle Service Fill ........................................................................................................................................... ...................................................... 4.0 qts. (3.8 L) 41TE Overhaul Fill ............................................................................................................................... ..................................................... 9.7 qts. (9.2 L) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 5184 Differential Fluid - A/T: Fluid Type Specifications Automatic Transmission Fluid Type ......................................................................................................... Mopar ATF+4 Automatic Transmission Fluid Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Specifications > Page 5185 Differential Fluid - A/T: Testing and Inspection 41TE - Automatic Transaxle Refer to Transmission Fluid, A/T. NOTE: The 41TE automatic transaxle has a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Specifications > Page 5186 Differential Fluid - A/T: Service and Repair 41TE - Automatic Transaxle Refer to Transmission Fluid, A/T. NOTE: The 41TE automatic transaxle has a common transmission and differential sump. Filling the transaxle accommodates the differential as well. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Specifications Extension Housing: Specifications Bolt, Extension Housing/Plate-to-Case ................................................................................................................................................... 28 Nm (21 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5194 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5195 Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage NUMBER: 21-014-07 GROUP: Transmission DATE: October 16, 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - **2008** (CS) Pacifica 1998-2003 (DN) Durango 2002 - **2008** (DR/DH/D1) Ram Truck 2007 - **2008** (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (GS) Chrysler Voyager (International Market) 2004 - **2008** (HB) Durango **2008 (HG) Aspen** 1995 - 2000 (JA) Cirrus/Stratus/Breeze Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5196 2007 - **2008** (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible 1996 - 2000 (JX) Sebring Convertible **2007 - 2008 (KA) Nitro** 2002 - 2007 (KJ) Liberty **2008 (KK) Liberty** **2008 (L2) 300C (China)** 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - **2008** (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - **2008** (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager **2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)** 1997-2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - **2008** (WK/WH) Grand Cherokee 2006 - **2008** (XK/XH) Commander 1989 - 1995 (YJ) Wrangler **1989 - 2001 (XJ) Cherokee** **1989 - 1993 (MJ) Comanche** 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: **AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is recommended for AW-4 (Asian Warner) transmissions** NOTE: This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5197 Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4® BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5198 Fluid - A/T: Technical Service Bulletins A/T - ATF+4 Fluid Usage/Applications NUMBER: 21-010-06 GROUP: Transmission DATE: April 14, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-004-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602) MODELS: 1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan 1989 - 2003 (AB) Ram Van/Wagon 1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram Truck 1989 - 1994 (AG) Daytona 1989 (AH) Lancer/Lebaron GTS 1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible 1989 - 1990 (AK) Aries/Reliant 1989 - 1990 (AL) Horizon/Omni 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue 1989 - 2004 (AN) Dakota 1989 - 1994 (AP) Shadow/Sundance 1990 - 1991 (AQ) Maserati 1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue 1994 - 2003 (BR/BE) Ram Truck 2004 - 2007 (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - 2007 (DR/DH/D1) Ram Truck 2007 (DC) Ram 3500 Cab Chassis 1995 - 2000 (FJ) Sebring/Avenger/Talon 1996 - 2000 (CS) Chrysler Voyager (International Market) 2004 - 2007 (HB) Durango 1995 - 2000 (JA) Cirrus/Stratus/Breeze 2007 (JK) Wrangler 2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5199 2007 (JS) Avenger/Sebring 1996 - 2000 (JX) Sebring Convertible 2002 - 2007 (KJ) Liberty 1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M 2005 - 2007 (LX/LE) 300/Magnum/Charger 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1995 - 2005 (PL) Neon 2002 - 2003 (PG) PT Cruiser (International Markets) 2001 - 2007 (PT) PT Cruiser 1997 - 2002 (PR) Prowler 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 1997 - 2006 (TJ) Wrangler 2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines 1999 - 2004 (WJ) Grand Cherokee 2005 - 2007 (WK/WH) Grand Cherokee 2006 - 2007 (XK/XH) Commander 1989 - 1995 (YJ) Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Markets) 1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer NOTE: This Service Bulletin DOES NOT apply to AW-4 transmissions, Sprinter transmissions, Crossfire transmissions, MK/PM vehicles equipped with Continuously Variable Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a W5J400 or NAG1 transmission (sales code DGJ). DISCUSSION: ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions. ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions EXCEPT FOR THOSE NOTED ABOVE. NOTE: ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE ANY OTHER FLUID. NOTE: ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4 can be used to top off vehicles that used ATF+3, ATF+2, or ATF+. NOTE: If ATF+4(R) is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid maintenance schedules listed for that model does not change. The service interval currently in effect for a given model should continue to be followed. Refer to the Service or Owners manual for maintenance schedule directions. In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to use ATF+4. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5200 BENEFITS ^ Better anti-wear properties ^ Improved rust/corrosion prevention ^ Controls oxidation ^ Eliminates deposits ^ Controls friction ^ Retains anti-foaming properties ^ Superior properties for low temperature operation FLUID COLOR Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer indicators of fluid condition and do not necessarily support a fluid change. PARTS REQUIRED: POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Automatic Transaxle Service Fill ........................................................................................................................................... ...................................................... 3.8Liters (4.0 Qt) 41TE Overhaul Fill ............................................................................................................................... ...................................................... 9.2Liters (9.7 Qt) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 5203 Fluid - A/T: Fluid Type Specifications Automatic Transmission Fluid Type .............................................................................................................. Mopar ATF+4 Automatic Transmission Fluid Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Diagnosis and Testing Fluid - A/T: Testing and Inspection Diagnosis and Testing Effects of Incorrect Fluid Level DIAGNOSIS AND TESTING - EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation and varnish build up which interferes with valve and clutch operation. Foaming also causes fluid expansion, which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Fluid Contamination DIAGNOSIS AND TESTING - FLUID CONTAMINATION Transmission fluid contamination is generally a result of: * adding incorrect fluid * failure to clean dipstick and fill tube when checking level * engine coolant entering the fluid * internal failure that generates debris * overheat that generates sludge (fluid breakdown) * failure to reverse flush cooler and lines after repair * failure to replace contaminated converter after repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. The transmission cooler and lines should be reverse flushed whenever a malfunction generates sludge and/or debris. The torque converter should also be replaced at the same time. Failure to flush the cooler and lines will result in recontamination. Flushing applies to auxiliary coolers as well. The torque converter should also be replaced whenever a failure generates sludge and debris. This is necessary because normal converter flushing procedures will not remove all contaminants. Causes of Burnt Fluid DIAGNOSIS AND TESTING - CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and/or auxiliary cooler. This condition is usually the result of a faulty or improperly installed drainback valve, a damaged main cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Diagnosis and Testing > Page 5206 Fluid - A/T: Testing and Inspection Fluid Level and Condition Check 41TE - Automatic Transaxle FLUID LEVEL AND CONDITION CHECK NOTE: Only transmission fluid of the type labeled Mopar ATF+4 (Automatic Transmission Fluid-Type 9602) should be used in this transaxle. FLUID LEVEL CHECK The transmission sump has a fluid level indicator (dipstick) to check oil similar to most automatic transmissions. It is located on the left side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P Park and N Neutral positions. Place the selector lever in P Park to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature 82° C (180° F), the fluid level is correct if it is in the HOT region on the oil level indicator (Fig. 210). The fluid level should be within the COLD region of the dipstick at 27° C (80° F) fluid temperature. FLUID LEVEL CHECK USING DRB NOTE: Engine and Transaxle should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Hook up DRB scan tool and select transmission. 3. Select sensors. 4. Read the transmission temperature value. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Diagnosis and Testing > Page 5207 5. Compare the fluid temperature value with the fluid temperature chart (Fig. 211). 6. Adjust transmission fluid level shown on the indicator according to the chart. 7. Check transmission for leaks. Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transaxle has too much fluid, the gears churn up foam and cause the same conditions, which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken for a leak. FLUID CONDITION Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle recondition is probably required. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. Mopar ATF+4 (Automatic Transmission Fluid Type 9602) when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 40TE Fluid - A/T: Service and Repair 40TE Fluid Level and Condition Check FLUID LEVEL AND CONDITION CHECK NOTE: Only transmission fluid of the type labeled Mopar ATF+4 (Automatic Transmission Fluid) should be used in this transaxle. FLUID LEVEL CHECK The transmission sump has a fluid level indicator (dipstick) to check oil similar to most automatic transmissions. It is located on the left side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P Park and N Neutral positions. Place the selector lever in P Park to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature 82° C (180° F), the fluid level is correct if it is in the HOT region on the oil level indicator (Fig. 187). The fluid level should be within the COLD region of the dipstick at 27° C (80° F) fluid temperature. FLUID LEVEL CHECK USING ORB NOTE: Engine and Transaxle should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Hook up DRB scan tool and select transmission. 3. Select sensors. 4. Read the transmission temperature value. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 40TE > Page 5210 5. Compare the fluid temperature value with the fluid temperature chart (Fig. 188). 6. Adjust transmission fluid level shown on the indicator according to the chart. 7. Check transmission for leaks. Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transaxle has too much fluid, the gears churn up foam and cause the same conditions which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken for a leak. FLUID CONDITION Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle recondition is probably required. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. Mopar ATF+4 (Automatic Transmission Fluid) when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Fluid and Filter Service STANDARD PROCEDURE - FLUID AND FILTER SERVICE NOTE: Refer to the maintenance schedules in LUBRICATION and MAINTENANCE, or the vehicle owner's manual, for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: Only fluids of the type labeled leopard ATF+4 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed. FLUID/FILTER SERVICE (RECOMMENDED) 1. Raise vehicle on a hoist. Refer to LUBRICATION and MAINTENANCE for proper procedures. Place a drain container with a large opening, under transaxle oil pan. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 40TE > Page 5211 2. Remove both engine mount-to-engine crossmember cradle nuts. Using suitable screw jack and wood block, raise engine and transmission slightly to facilitate transaxle oil pan removal and installation. 3. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 4. Install a new filter and o-ring on bottom of the valve body (Fig. 189). 5. Clean the oil pan and magnet. Reinstall pan using new Mopar Silicone Adhesive sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 6. Pour four quarts of Mopar ATF+4 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick (Fig. 190). 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). Refer to Fluid Level and Condition Check for the proper fluid fill procedure. 10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE) 1. When performing the fluid suction method, make sure the transaxle is at full operating temperature. 2. To perform the dipstick tube fluid suction method, use a suitable fluid suction device (Vacula TM or equivalent). 3. Insert the fluid suction line into the dipstick tube. NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will ensure complete evacuation of the fluid in the pan. 4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5. Remove the suction line from the dipstick tube. 6. Pour four quarts of Mopar ATF+4 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 40TE > Page 5212 position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3mm (1/8 inch) below the lowest mark on the dipstick (Fig. 190). 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). 10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 40TE > Page 5213 Fluid - A/T: Service and Repair 41TE 41TE - Automatic Transaxle FLUID LEVEL AND CONDITION CHECK NOTE: Only transmission fluid of the type labeled Mopar ATF+4 (Automatic Transmission Fluid-Type 9602) should be used in this transaxle. FLUID LEVEL CHECK The transmission sump has a fluid level indicator (dipstick) to check oil similar to most automatic transmissions. It is located on the left side of the engine. Be sure to wipe all dirt from dipstick handle before removing. The torque converter fills in both the P Park and N Neutral positions. Place the selector lever in P Park to be sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute, with the vehicle on level ground. At normal operating temperature 82° C (180° F), the fluid level is correct if it is in the HOT region on the oil level indicator (Fig. 210). The fluid level should be within the COLD region of the dipstick at 27° C (80° F) fluid temperature. FLUID LEVEL CHECK USING DRB NOTE: Engine and Transaxle should be at normal operating temperature before performing this procedure. 1. Start engine and apply parking brake. 2. Hook up DRB scan tool and select transmission. 3. Select sensors. 4. Read the transmission temperature value. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 40TE > Page 5214 5. Compare the fluid temperature value with the fluid temperature chart (Fig. 211). 6. Adjust transmission fluid level shown on the indicator according to the chart. 7. Check transmission for leaks. Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid. As in any hydraulic system, air bubbles make the fluid spongy, therefore, pressures will be low and build up slowly. Improper filling can also raise the fluid level too high. When the transaxle has too much fluid, the gears churn up foam and cause the same conditions, which occur with a low fluid level. In either case, air bubbles can cause overheating and/or fluid oxidation, and varnishing. This can interfere with normal valve, clutch, and accumulator operation. Foaming can also result in fluid escaping from the transaxle vent where it may be mistaken for a leak. FLUID CONDITION Along with fluid level, it is important to check the condition of the fluid. When the fluid smells burned, and is contaminated with metal or friction material particles, a complete transaxle recondition is probably required. Be sure to examine the fluid on the dipstick closely. If there is any doubt about its condition, drain out a sample for a double check. Mopar ATF+4 (Automatic Transmission Fluid Type 9602) when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. After the fluid has been checked, seat the dipstick fully to seal out water and dirt. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 40TE Fluid Filter - A/T: Service and Repair 40TE STANDARD PROCEDURE - FLUID AND FILTER SERVICE NOTE: Refer to the maintenance schedules in LUBRICATION and MAINTENANCE, or the vehicle owner's manual, for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: Only fluids of the type labeled leopard ATF+4 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed. FLUID/FILTER SERVICE (RECOMMENDED) 1. Raise vehicle on a hoist. Refer to LUBRICATION and MAINTENANCE for proper procedures. Place a drain container with a large opening, under transaxle oil pan. 2. Remove both engine mount-to-engine crossmember cradle nuts. Using suitable screw jack and wood block, raise engine and transmission slightly to facilitate transaxle oil pan removal and installation. 3. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 4. Install a new filter and o-ring on bottom of the valve body (Fig. 189). 5. Clean the oil pan and magnet. Reinstall pan using new Mopar Silicone Adhesive sealant. Tighten oil pan bolts to 19 Nm (165 inch lbs.). 6. Pour four quarts of Mopar ATF+4 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the lowest mark on the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 40TE > Page 5219 dipstick (Fig. 190). 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). Refer to Fluid Level and Condition Check for the proper fluid fill procedure. 10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE) 1. When performing the fluid suction method, make sure the transaxle is at full operating temperature. 2. To perform the dipstick tube fluid suction method, use a suitable fluid suction device (Vacula TM or equivalent). 3. Insert the fluid suction line into the dipstick tube. NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will ensure complete evacuation of the fluid in the pan. 4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5. Remove the suction line from the dipstick tube. 6. Pour four quarts of Mopar ATF+4 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3mm (1/8 inch) below the lowest mark on the dipstick (Fig. 190). 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). 10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 40TE > Page 5220 Fluid Filter - A/T: Service and Repair 41TE 41TE - Automatic Transmission STANDARD PROCEDURE - FLUID AND FILTER SERVICE NOTE: Refer to the vehicle owner's manual, for the recommended maintenance (fluid/filter change) intervals for this transaxle. NOTE: Only fluids of the type labeled leopard ATF+4 (Automatic Transmission Fluid) Type 9602 should be used. A filter change should be made at the time of the transmission oil change. The magnet (on the inside of the oil pan) should also be cleaned with a clean, dry cloth. NOTE: If the transaxle is disassembled for any reason, the fluid and filter should be changed. FLUID/FILTER SERVICE (RECOMMENDED) 1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body (Fig. 212). 4. Clean the oil pan and magnet. Reinstall pan using new Mopar Silicone Adhesive sealant. Tighten oil pan bolts to............19 Nm (165 inch lbs.). 5. Pour four quarts of Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 7. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3mm (1/8 inch) below the lowest mark on the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > 40TE > Page 5221 dipstick (Fig. 213). 8. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). Refer to Fluid Level and Condition Check for the proper fluid fill procedure. 9. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. DIPSTICK TUBE FLUID SUCTION METHOD (ALTERNATIVE) 1. When performing the fluid suction method, make sure the transaxle is at full operating temperature. 2. To perform the dipstick tube fluid suction method, use a suitable fluid suction device (Vacula or equivalent). 3. Insert the fluid suction line into the dipstick tube. NOTE: Verify that the suction line is inserted to the lowest point of the transaxle oil pan. This will ensure complete evacuation of the fluid in the pan. 4. Follow the manufacturers recommended procedure and evacuate the fluid from the transaxle. 5. Remove the suction line from the dipstick tube. 6. Pour four quarts of Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 through the dipstick opening. 7. Start engine and allow to idle for at least one minute. Then, with parking and service brakes applied, move selector lever momentarily to each position, ending in the park or neutral position. 8. Check the transaxle fluid level and add an appropriate amount to bring the transaxle fluid level to 3 mm (1/8 inch) below the lowest mark on the dipstick (Fig. 213). 9. Recheck the fluid level after the transaxle has reached normal operating temperature (180°F.). 10. To prevent dirt from entering transaxle, make certain that dipstick is fully seated into the dipstick opening. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Oil pan-to-case bolts ............................................................................................................................ ................................................ 19 Nm (165 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Testing and Inspection > Pressure Switch States Pressure Switch States Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Testing and Inspection > Pressure Switch States > Page 5230 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications Fluid Pump: Specifications 41TE - Automatic Transmission Bolt, Oil Pump-to-Case ........................................................................................................................ ................................................... 27 Nm (20 ft. lbs.) Bolt, Oil Pan-to-Case ......................................... ............................................................................................................................... 19 Nm (165 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Fluid Pump: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission OIL PUMP - DESCRIPTION The oil pump is located in the pump housing inside the bell housing of the transaxle case (Fig. 291). The oil pump consists of an inner and outer gear, a housing, and a cover that also serves as the reaction shaft support. OPERATION As the torque converter rotates, the converter hub rotates the inner and outer gears. As the gears rotate, the clearance between the gear teeth increases in the crescent area, and creates a suction at the inlet side of the pump. This suction draws fluid through the pump inlet from the oil pan. As the clearance between the gear teeth in the crescent area decreases, it forces pressurized fluid into the pump outlet and to the valve body. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5236 Fluid Pump: Description and Operation 40TE Automatic Transaxle OIL PUMP DESCRIPTION The oil pump is located in the pump housing inside the bell housing of the transaxle case (Fig. 255). The oil pump consists of an inner and outer gear, a housing, and a cover that also serves as the reaction shaft support. OPERATION As the torque converter rotates, the converter hub rotates the inner and outer gears. As the gears rotate, the clearance between the gear teeth increases in the crescent area, and creates a suction at the inlet side of the pump. This suction draws fluid through the pump inlet from the oil pan. As the clearance between the gear teeth in the crescent area decreases, it forces pressurized fluid into the pump outlet and to the valve body. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Description and Operation > Page 5237 Fluid Pump: Testing and Inspection 41TE - AUTOMATIC TRANSMISSION STANDARD PROCEDURE - OIL PUMP VOLUME CHECK Measuring oil pump output volume will determine if sufficient flow to the transmission oil cooler exists, and whether or not an internal transmission failure is present. Verify that transmission fluid is at the proper level. If adding fluid is necessary, fill to the proper level with Mopar ATF+4 (Automatic Transmission Fluid-Type 9602). The following procedure is to check oil pump output volume: 1. Using hose cutters or a suitable blade, cut the "to cooler" (Fig. 292) line off flush with the cooler inlet fitting and place a collection container under the open line. CAUTION: With the fluid set at the proper level, fluid collection should not exceed (1) quart or internal damage to the transmission may occur. 2. Start engine and run at curb idle speed, with the shift selector in neutral. 3. If one quart of ATF is collected in 20 seconds or less, flow is within acceptable limits. If fluid flow is intermittent or it takes more than 20 seconds to collect one quart of ATF, Refer to DIAGNOSIS AND TESTING. 4. Inspect the cooler hose for damage. Replace if necessary. 5. Re-connect the to cooler line to the transmission using a service splice kit. Refer to instructions included with the kit. 6. Refill the transaxle to proper level with Mopar ATF+4 (Automatic Transmission Fluid-Type 9602). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly Fluid Pump: Service and Repair Disassembly 41TE - Automatic Transmission DISASSEMBLY When disassembling the transaxle it is necessary to inspect the oil pump for wear and damage. 1. Remove the reaction shaft support bolts. 2. Remove reaction shaft support from pump housing (Fig. 293). 3. Remove the pump gears (Fig. 294) and check for wear and damage on pump housing and gears. 4. Re-install the gears and check clearances. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 5240 5. Measure the clearance between the outer gear and the pump pocket (Fig. 295). Clearance should be 0.089 - 0.202 mm (0.0035 - 0.0079 inch). 6. Measure clearance between outer gear and crescent. Clearance should be 0.060 - 0.298 mm (0.0023 - 0.0117 inch). 7. Measure clearance between inner gear and crescent. Clearance should be 0.093 - 0.385 mm (0.0036 - 0.0151 inch). 8. Position an appropriate piece of Plastigage across both pump gears. 9. Align the Plastigage to a flat area on the reaction shaft support housing. 10. Install the reaction shaft to the pump housing. Tighten the bolts to 27 Nm (20 ft. lbs.). 11. Remove bolts and carefully separate the housings. Measure the Plastigage following the instructions supplied. 12. Clearance between outer gear side and the reaction shaft support should be 0.020 - 0.046 mm (0.0008 - 0.0018 inch). Clearance between inner gear side and the reaction shaft support should be 0.020 - 0.046 mm (0.0008 - 0.0018 inch). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Disassembly > Page 5241 Fluid Pump: Service and Repair Assembly 41TE - Automatic Transmission ASSEMBLY 1. Assemble oil pump as shown in (Fig. 296) 2. Install and torque reaction shaft support-to-oil pump housing bolts to 28 Nm (20 ft. lbs.) torque. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Planetary Gears: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission PLANETARY GEARTRAIN - DESCRIPTION The planetary geartrain is located between the input clutch assembly and the rear of the transaxle case. The planetary geartrain consists of two sun gears, two planetary carriers, two annulus (ring) gears, and one output shaft (Fig. 297). OPERATION The planetary geartrain utilizes two planetary gear sets that connect the transmission input shaft to the output shaft. Input and holding clutches drive or lock different planetary members to change output ratio or direction. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5246 Planetary Gears: Description and Operation 40TE Automatic Transaxle PLANETARY GEARTRAIN DESCRIPTION The planetary geartrain is located between the input clutch assembly and the rear of the transaxle case. The planetary geartrain consists of two sun gears, two planetary carriers, two annulus (ring) gears, and one output shaft (Fig. 260). OPERATION The planetary geartrain utilizes two planetary gear sets that connect the transmission input shaft to the output shaft. Input and holding clutches drive or lock different planetary members to change output ratio or direction. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation Pressure Regulating Solenoid: Description and Operation SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION The Solenoid/Pressure Switch Assembly (Fig. 276) is external to the transaxle and mounted to the transaxle case. The assembly consists of four solenoids that control hydraulic pressure to the LR/CC, 2/4, OD, and UD friction elements. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the PCM/TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The PCM/TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which by design allow fluid to pass through in their relaxed or "off" state. This allows transaxle limp-in (P, R, N, 2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the PCM/TCM during this test. It no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The PCM/TCM relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the PCM/TCM detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the PCM/TCM for the correct states (open or closed) in each gear as shown in the following chart: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 5250 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the PCM/TCM senses any switch open or closed at the wrong time in a given gear. The PCM/TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the PCM/TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 5251 Pressure Regulating Solenoid: Service and Repair SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect solenoid/pressure switch assembly connector (Fig. 277). 4. Disconnect input speed sensor connector (Fig. 277). 5. Remove input speed sensor (Fig. 278). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 5252 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 279). 7. Remove solenoid/pressure switch assembly and gasket (Fig. 280). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 280). 2. Install and torque three (3) bolts (Fig. 279) to 13 Nm (110 inch lbs.). 3. Install input speed sensor (Fig. 278) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector (Fig. 277). 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 inch lbs.) (Fig. 277). 6. Install air cleaner assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations Control Module: Locations Control Module Locations NGC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 5257 Control Module: Description and Operation Fig.14 Transmission Control Module (TCM) Location The Transmission Control Module (TCM) is located behind the left fender and is fastened with three screws to three clips in the left frame rail forward of the suspension (Fig. 14). The TCM is the controlling unit for all electronic operations of the transaxle. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transaxle. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the J1850 communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor (CKP) - Transmission Range Sensor (TRS) - Pressure Switches (L/R, 2/4, OD) - Transmission Temperature Sensor (Integral to TRS) - Input Shaft Speed Sensor - Output Shaft Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Speed Control ON/OFF Switch - Engine Coolant Temperature - Ambient/Battery Temperature - Brake Switch Status - DRB Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids (LR/CC, 2/4, OD and UD) - Vehicle Speed (to PCM) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 5258 - Torque Reduction Request (to PCM) An example of a TCM indirect output is: - Transmission Temperature (to PCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indices (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB scan tool) Clutch Volume Index (CVI) An important function of the TCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.15 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transaxle gear ratio. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 15). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 5259 Clutch Volumes Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 5260 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 5261 Control Module: Service and Repair ELECTRONIC PINION FACTOR (IF APPLICABLE) NOTE: After replacing the EATX/PCM, you must reprogram pinion factor. In some vehicle applications, the pinion factor is a fixed value and cannot be changed or updated. The transmission output speed signal supplies distance pulses to the control module, which are used to calculate speed and mileage. A pinion factor is stored in the control module in order to provide the appropriate distance pulses for other vehicle systems. The pinion factor is programmed into the control module at the assembly plant. The pinion factor must be set when replacing the control module. If the pinion factor is not set or incorrectly set, any speed related functions will not operate correctly i.e. speedometer, speed control, rolling door locks, other control modules will be affected that depend on speed information. Using the following steps, the pinion factor can be checked and/or reset using the DRBIII: 1. Select Transmission system, then Miscellaneous functions, then Pinion Factor. The DRBIII will display the current tire size. 2. If the tire size is incorrect, press the Enter key and then select the correct size. 3. Press the Page Back key to exit the reset procedure. Notes About Electronic Pinion Factor Features The nature of the electronic pinion factor requires that certain features must be taken into consideration. ^ If no pinion factor is stored in an installed control module, the vehicle speedometer will not operate, engine speed will be limited to 2300 RPM, and catalyst damage may occur. ^ Selecting a wrong tire size will cause the speedometer to be inaccurate and will also cause any speed related features to operate improperly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5265 Transmission Control System Relay: Diagrams Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5266 Transmission Control Relay (EATX) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Transmission Control System Relay: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION CONTROL RELAY - DESCRIPTION The transmission control relay (Fig. 336) is located in the Intelligent Power Module (IPM), which is located on the left side of the engine compartment between the battery and left fender. OPERATION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5269 Transmission Control System Relay: Description and Operation 40TE Automatic Transaxle TRANSMISSION CONTROL RELAY DESCRIPTION The transmission control relay (Fig. 302) is located in the Intelligent Power Module (IPM), which is located on the left side of the engine compartment between the battery and left fender. OPERATION The Transmission Control Relay is supplied fused B+ voltage, energized by the PCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the PCM energizes the relay. Prior to this, the PCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the PCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 40TE Automatic Transaxle Seals and Gaskets: Service and Repair 40TE Automatic Transaxle SEAL OIL PUMP REMOVAL 1. Remove transaxle from vehicle. 2. Using Tool C-3981 -B. remove oil pump seal (Fig. 261). INSTALLATION 1. Using Tool C-4193, install oil pump seal (Fig. 262). 2. Install transaxle to vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > 40TE Automatic Transaxle > Page 5274 Seals and Gaskets: Service and Repair 41TE Automatic Transmission 41TE - Automatic Transmission SEAL, OIL PUMP REMOVAL 1. Remove transaxle from vehicle. 2. Using Tool C-3981 -B. remove oil pump seal (Fig. 298). INSTALLATION 1. Using Tool C-4193, install oil pump seal (Fig. 299). 2. Install transaxle to vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Testing and Inspection > Pressure Switch States Pressure Switch States Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Testing and Inspection > Pressure Switch States > Page 5281 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR Sensor, Transmission Range Sensor ...................................................................................................................................................... 5 Nm (45 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 5287 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5288 Transmission Range Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 337). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 338). OPERATION The Transmission Range Sensor (TRS) (Fig. 337) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5291 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 338) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5292 Transmission Position Switch/Sensor: Description and Operation 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 303). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM/TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 304). OPERATION The Transmission Range Sensor (TRS) (Fig. 303) communicates Shift Lever Position (SLP) to the PCM/TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the PCM/TCM receives from four sense circuits. The PCM/TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the PCM/TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5293 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 304) that the PCM/TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the PCM/TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the PCM/TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 5294 Transmission Position Switch/Sensor: Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle Transmission Position Switch/Sensor: Service and Repair 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 305). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 305) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5297 Transmission Position Switch/Sensor: Service and Repair 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 339). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 339) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5298 Transmission Position Switch/Sensor: Service and Repair 41TE REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 343). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 343) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications 41TE - Automatic Transmission Sensor, Input Speed ............................................................................................................................ .................................................... 27 Nm (20 ft. lbs.) Sensor, Output Speed ...................................... ........................................................................................................................................ 27 Nm (20 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 5304 Transmission Speed Sensor: Connector Locations Transmission Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 5305 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5306 Transmission Speed Sensor: Diagrams Input Speed Sensor Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle Transmission Speed Sensor: Description and Operation 40TE Automatic Transaxle Speed Sensor Input INPUT SPEED SENSOR DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case. The Input Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5309 The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as input shaft rpm. The PCM/TCM compares the input speed signal with output speed signal to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The PCM/TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Speed Sensor Output OUTPUT SPEED SENSOR DESCRIPTION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5310 The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case. The Output Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as output shaft rpm. The PCM/TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation Vehicle Speed Signal The vehicle speed signal is taken from the Output Speed Sensor. The PCM converts this signal into a pulse per mile and sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5311 Transmission Speed Sensor: Description and Operation 41TE Automatic Transmission Input Speed Sensor INPUT SPEED SENSOR DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case. The Input Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5312 The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as input shaft rpm. The PCM/TCM compares the input speed signal with output speed signal to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The PCM/TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Output Speed Sensor OUTPUT SPEED SENSOR DESCRIPTION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5313 The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case. The Output Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as output shaft rpm. The PCM/TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation Vehicle Speed Signal The vehicle speed signal is taken from the Output Speed Sensor. The PCM converts this signal into a pulse per mile and sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle Transmission Speed Sensor: Service and Repair 40TE Automatic Transaxle Input Speed Sensor SPEED SENSOR INPUT REMOVAL 1. Disconnect battery negative cable. 2. Disconnect input speed sensor connector (Fig. 284). 3. Unscrew and remove input speed sensor (Fig. 285). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5316 4. Inspect speed sensor o-ring (Fig. 286) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 286). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.) (Fig. 285). 3. Connect speed sensor connector (Fig. 284). 4. Connect battery negative cable. Output Speed Sensor SPEED SENSOR OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector (Fig. 290). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5317 4. Unscrew and remove output speed sensor (Fig. 291). 5. Inspect speed sensor o-ring (Fig. 292) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 292). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector (Fig. 290). 4. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5318 Transmission Speed Sensor: Service and Repair 41TE Automatic Transmission Input Speed Sensor SPEED SENSOR INPUT REMOVAL 1. Disconnect battery negative cable. 2. Disconnect input speed sensor connector (Fig. 284). 3. Unscrew and remove input speed sensor (Fig. 285). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5319 4. Inspect speed sensor o-ring (Fig. 286) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 286). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.) (Fig. 285). 3. Connect speed sensor connector (Fig. 284). 4. Connect battery negative cable. Output Speed Sensor SPEED SENSOR OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector (Fig. 290). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5320 4. Unscrew and remove output speed sensor (Fig. 291). 5. Inspect speed sensor o-ring (Fig. 292) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 292). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector (Fig. 290). 4. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 5324 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5329 Steering Column Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5330 Brake Transmission shift Interlock Solenoid Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5331 Shift Interlock Solenoid: Service and Repair SHIFT INTERLOCK SOLENOID REMOVAL 1. Disconnect battery negative cable. 2. Remove instrument panel lower shroud (Fig. 268). 3. Remove knee bolster (Fig. 269). 4. Remove steering column lower shroud. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5332 5. Disconnect Brake/Transmission Shift Interlock (BTSI) solenoid connector (Fig. 270). 6. Remove two (2) solenoid-to-column screws (Fig. 271). 7. Remove solenoid. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5333 1. Place interlock solenoid into position ensuring hook on end of solenoid plunger engages gearshift lever pawl pin. Install and tighten screws (Fig. 272). 2. Verify gearshift lever is in PARK (P) and connect solenoid connector (Fig. 273). 3. Install steering column lower shroud. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5334 4. Install knee bolster (Fig. 274). 5. Install instrument panel lower silencer (Fig. 275). 6. Connect battery negative cable. 7. Verify proper shift interlock system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications 41TE - Automatic Transaxle SOLENOID/PRESSURE SWITCH ASSY Bolt, Solenoid/Pressure Switch Assy. Connector .............................................................................................................................. 12 Nm (110 inch lbs.) Screw, Solenoid/Pressure Switch Assy. Connector ............................................................................................................................... 4 Nm (35 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 5338 Shift Solenoid: Locations Transmission Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 5339 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 5340 Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 5341 Transmission Solenodi/pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 5342 Shift Solenoid: Description and Operation 41TE - Automatic Transaxle SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION The Solenoid/Pressure Switch Assembly (Fig. 313) is external to the transaxle and mounted to the transaxle case. The assembly consists of four solenoids that control hydraulic pressure to the LR/CC, 2/4, OD, and UD friction elements. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which by design allow fluid to pass through in their relaxed or "off" state. This allows transaxle limp-in (P, R, N, 2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. It no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11 - 23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following chart: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 5343 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 5344 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 5345 Shift Solenoid: Service and Repair 41TE - Automatic Transaxle SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect solenoid/pressure switch assembly connector. 4. Disconnect input speed sensor connector. 5. Remove input speed sensor (Fig. 314). 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 315). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 5346 7. Remove solenoid/pressure switch assembly and gasket (Fig. 316). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 316). 2. Install and torque three (3) bolts (Fig. 315) to 13 Nm (110 inch lbs.). 3. Install input speed sensor (Fig. 314) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector. 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 inch lbs.). 6. Install air cleaner assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 21-005-04A > Oct > 04 > A/T - Coastdown Ticking Noise Shift Cable: Customer Interest A/T - Coastdown Ticking Noise NUMBER: 21-005-04 REV. A GROUP: Transmission DATE: October 9, 2004 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-005-04, DATED APRIL 6, 2004, WHICH SHOULD BF REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES UPDATES FOR THE SUBJECT, SYMPTOM/CONDITION, BUILD DATES AND REPAIR PROCEDURE. SUBJECT: **Coastdown Ticking Sound Between 40 mph and 0 mph and/or Transfer Gear Whine Sound Between 20 mph and 65 mph Either Accelerating or Decelerating** OVERVIEW: This bulletin involves applying mastic patches to the gearshift control cable. MODELS: 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan/Voyager NOTE: **This bulletin applies to vehicles equipped with an automatic transmission (sales code DGB or DGL) built on or before October 19, 2004 (MDH 1019XX) at St. Louis Assembly plant and Windsor Assembly plant or November 3, 2004 (MDH 1103XX) at Gratz Assembly plant**. SYMPTOM/CONDITION: **Vehicle operator may experience one of the following: A ticking sound while vehicle is coasting down between 40 mph (64 kph) and 0 mph (0 kph). This condition may also be described as a rattle or a flutter. A transfer gear whine sound while vehicle is either accelerating or coasting down between 20 mph (32 kph) and 65 mph (105 kph). This condition may also be described as a whistling sound**. PARTS REQUIRED: REPAIR PROCEDURE: 1. Gain access to the gear shift cable at transmission. If a mastic patch is present continue to Step # 9. If a mastic patch is not present continue to Step # 2. 2. Disconnect gear shift cable at manual valve lever. 3. Disconnect gear shift cable from upper mount bracket. 4. Disengage grommet from dash panel and pull gear shift cable inside the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 21-005-04A > Oct > 04 > A/T - Coastdown Ticking Noise > Page 5356 5. Wrap one mastic patch around the gear shift cable flush with the collar on the transmission side of the cable. Squeeze ends of mastic to cable (Fig. 1). CAUTION: Roll the mastic patch around the cable to reduce the possibility of interference with other components. 6. Push gear shift cable through dash panel and engage grommet into dash panel. 7. Connect gear shift cable to upper mount bracket. 8. Connect gear shift cable to manual valve lever. 9. Wrap one mastic patch around the gear shift cable one (1") inch from the conduit on the I/P side of the cable (Fig. 2). NOTE: If mastic patches are already present on the I/P side of the cable cut them off using scissors. 10. Wrap two additional mastic patches over the top of the first mastic patch applied in the previous step. Squeeze ends of mastic to cable (Fig. 2). 11. Start the engine and rotate the steering wheel from right to left and check for interference with the newly installed mastic patch inside of the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 21-005-04A > Oct > 04 > A/T - Coastdown Ticking Noise > Page 5357 vehicle. If interference is present adjust as necessary. 12. Drive the vehicle above 64 kph (40 mph) and then let the vehicle coast down below 16 kph (10 mph) and listen for a ticking sound. **Slowly accelerate the vehicle above 65 mph (105 kph) and then let the vehicle coast down below 20 mph (32 kph) and listen for gear whine sound** If the sound is still present at coastdown further diagnosis is required. Refer to 21 TRANSMISSION/TRANSAXLE/AUTOMATIC - 41TE or 40TE/DIAGNOSIS available in TechCONNECT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 21-005-04A > Oct > 04 > A/T - Coastdown Ticking Noise Shift Cable: All Technical Service Bulletins A/T - Coastdown Ticking Noise NUMBER: 21-005-04 REV. A GROUP: Transmission DATE: October 9, 2004 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 21-005-04, DATED APRIL 6, 2004, WHICH SHOULD BF REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES UPDATES FOR THE SUBJECT, SYMPTOM/CONDITION, BUILD DATES AND REPAIR PROCEDURE. SUBJECT: **Coastdown Ticking Sound Between 40 mph and 0 mph and/or Transfer Gear Whine Sound Between 20 mph and 65 mph Either Accelerating or Decelerating** OVERVIEW: This bulletin involves applying mastic patches to the gearshift control cable. MODELS: 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan/Voyager NOTE: **This bulletin applies to vehicles equipped with an automatic transmission (sales code DGB or DGL) built on or before October 19, 2004 (MDH 1019XX) at St. Louis Assembly plant and Windsor Assembly plant or November 3, 2004 (MDH 1103XX) at Gratz Assembly plant**. SYMPTOM/CONDITION: **Vehicle operator may experience one of the following: A ticking sound while vehicle is coasting down between 40 mph (64 kph) and 0 mph (0 kph). This condition may also be described as a rattle or a flutter. A transfer gear whine sound while vehicle is either accelerating or coasting down between 20 mph (32 kph) and 65 mph (105 kph). This condition may also be described as a whistling sound**. PARTS REQUIRED: REPAIR PROCEDURE: 1. Gain access to the gear shift cable at transmission. If a mastic patch is present continue to Step # 9. If a mastic patch is not present continue to Step # 2. 2. Disconnect gear shift cable at manual valve lever. 3. Disconnect gear shift cable from upper mount bracket. 4. Disengage grommet from dash panel and pull gear shift cable inside the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 21-005-04A > Oct > 04 > A/T - Coastdown Ticking Noise > Page 5363 5. Wrap one mastic patch around the gear shift cable flush with the collar on the transmission side of the cable. Squeeze ends of mastic to cable (Fig. 1). CAUTION: Roll the mastic patch around the cable to reduce the possibility of interference with other components. 6. Push gear shift cable through dash panel and engage grommet into dash panel. 7. Connect gear shift cable to upper mount bracket. 8. Connect gear shift cable to manual valve lever. 9. Wrap one mastic patch around the gear shift cable one (1") inch from the conduit on the I/P side of the cable (Fig. 2). NOTE: If mastic patches are already present on the I/P side of the cable cut them off using scissors. 10. Wrap two additional mastic patches over the top of the first mastic patch applied in the previous step. Squeeze ends of mastic to cable (Fig. 2). 11. Start the engine and rotate the steering wheel from right to left and check for interference with the newly installed mastic patch inside of the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 21-005-04A > Oct > 04 > A/T - Coastdown Ticking Noise > Page 5364 vehicle. If interference is present adjust as necessary. 12. Drive the vehicle above 64 kph (40 mph) and then let the vehicle coast down below 16 kph (10 mph) and listen for a ticking sound. **Slowly accelerate the vehicle above 65 mph (105 kph) and then let the vehicle coast down below 20 mph (32 kph) and listen for gear whine sound** If the sound is still present at coastdown further diagnosis is required. Refer to 21 TRANSMISSION/TRANSAXLE/AUTOMATIC - 41TE or 40TE/DIAGNOSIS available in TechCONNECT. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Page 5365 Shift Cable: Adjustments 41TE - Automatic Transmission GEARSHIFT CABLE ADJUSTMENT - VERIFICATION 1. Place gearshift lever in gated park (P). 2. Attempt to move vehicle by rocking back and forth on level ground. If vehicle does not move, attempt to start engine. If engine starts, the park position is correct. 3. Set parking brake. 4. Turn key to on/run and depress brake pedal. Place gearshift lever in neutral (N). 5. Attempt to start engine. If engine starts in both neutral (N) or park (P), gearshift cable is adjusted properly. No adjustment is required. 6. If engine does not start in either park (P) or neutral (N), perform adjustment procedure. ADJUSTMENT 1. Park the vehicle on level ground and set the parking brake. 2. Place the gearshift lever in gated park (P) and remove ignition key. 3. Loosen the cable adjustment screw at the transaxle manual valve lever (Fig. 224). 4. Pull the gearshift lever fully forward to the park detent position. 5. Release the park brake, then rock the vehicle to assure it is in park. Reset the park brake. 6. Tighten the cable adjustment screw to 8 Nm (70 inch lbs.). Gearshift cable should now be properly adjusted. 7. Verify adjustment by using the verification procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle Shift Cable: Service and Repair 40TE Automatic Transaxle GEAR SHIFT CABLE REMOVAL 1. Disconnect battery cables. 2. Remove battery shield. 3. Remove battery. 4. Remove speed control servo and position out of way. 5. Disconnect gear shift cable at manual valve lever (Fig. 191). 6. Disconnect gear shift cable from upper mount bracket (Fig. 191). 7. Remove instrument panel lower silencer (Fig. 192). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5368 8. Remove knee bolster (Fig. 193). 9. Disconnect gear shift cable from gear shift lever (Fig. 194). 10. Remove gear shift cable from column bracket (Fig. 194). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5369 11. Disengage grommet from dash panel (Fig. 195) and remove gear shift cable from inside vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5370 Shift Cable: Service and Repair 41TE Automatic Transmission 41TE - Automatic Transmission GEARSHIFT CABLE - REMOVAL 1. Disconnect battery cables. 2. Remove battery shield. 3. Remove battery. 4. Remove speed control servo and position out of way. 5. Disconnect gear shift cable at manual valve lever (Fig. 214). 6. Disconnect gear shift cable from upper mount bracket (Fig. 214). 7. Remove instrument panel lower silencer (Fig. 215). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5371 8. Remove knee bolster (Fig. 216). 9. Disconnect gear shift cable from gear shift lever (Fig. 217). 10. Remove gear shift cable from column bracket (Fig. 217). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5372 11. Disengage grommet from dash panel (Fig. 218) and remove gear shift cable from inside vehicle. INSTALLATION 1. Fish gear shift cable dash panel opening into engine compartment and secure grommet (Fig. 219). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5373 2. Install gear shift cable through column bracket (Fig. 220) until audible "click" is heard. 3. Connect gear shift cable to gear shift lever (Fig. 220). 4. Install knee bolster (Fig. 221). 5. Install instrument panel lower silencer (Fig. 222). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5374 6. Install gear shift cable to transaxle upper mount bracket (Fig. 223). An audible "click" should be heard. 7. Connect gear shift cable end to transaxle manual valve lever (Fig. 223). 8. Adjust gearshift cable. 9. Install speed control servo into position. 10. Install battery. 11. Install battery shield. 12. Connect battery cables. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 41TE Automatic Transmission Torque Converter: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission TORQUE CONVERTER DESCRIPTION The torque converter (Fig. 327) is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine, a stator, an overrunning clutch, an impeller and an electronically applied converter clutch. The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The converter clutch engages in third gear. The torque converter hub drives the transmission oil (fluid) pump. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. CAUTION: The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid. If the fluid is contaminated, flush the fluid cooler and lines. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5379 IMPELLER The impeller (Fig. 328) is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving member of the system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5380 TURBINE The turbine (Fig. 329) is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5381 STATOR The stator assembly (Fig. 330) is mounted on a stationary shaft, which is an integral part of the oil pump. The stator is located between the impeller and turbine within the torque converter case (Fig. 331). The stator contains an over-running clutch, which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the torque converter is operational. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5382 Torque Converter: Description and Operation 40TE Automatic Transaxle TORQUE CONVERTER DESCRIPTION The torque converter (Fig. 293) is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine, a stator, an overrunning clutch, an impeller and an electronically applied converter clutch. The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The converter clutch engages in third gear. The torque converter hub drives the transmission oil (fluid) pump. The torque converter is a sealed, welded unit that is not repairable and is serviced as an assembly. IMPELLER Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5383 The impeller (Fig. 294) is an integral part of the converter housing. The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter. As the converter housing is rotated by the engine, so is the impeller, because they are one and the same and are the driving member of the system. TURBINE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5384 The turbine (Fig. 295) is the output, or driven, member of the converter. The turbine is mounted within the housing opposite the impeller, but is not attached to the housing. The input shaft is inserted through the center of the impeller and splined into the turbine. The design of the turbine is similar to the impeller, except the blades of the turbine are curved in the opposite direction. STATOR Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5385 The stator assembly (Fig. 296) is mounted on a stationary shaft which is an integral part of the oil pump. The stator is located between the impeller and turbine within the torque converter case (Fig. 297). The stator contains an over-running clutch, which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the torque converter is operational. TORQUE CONVERTER CLUTCH (TCC) The TCC (Fig. 298) was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shock-free power transfer, it is natural for all fluid couplings to slip. If the impeller and turbine were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston was added to the turbine, and a friction material was added to the inside of the front cover to provide this mechanical lock-up. OPERATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5386 The converter impeller (Fig. 299) (driving member), which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member), which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR Torque multiplication is achieved by locking the stator's over-running clutch to its shaft (Fig. 300). Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the over-running clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades and is redirected into a "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 2.4:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5387 way as to cause it to lock-up is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) In a standard torque converter, the impeller and turbine are rotating at about the same speed and the stator is freewheeling, providing no torque multiplication. By applying the turbine's piston to the front cover's friction material, a total converter engagement can be obtained. The result of this engagement is a direct 1:1 mechanical link between the engine and the transmission. The engagement and disengagement of the TCC are automatic and controlled by the Powertrain Control Module (PCM). The engagement cannot be activated in the lower gears because it eliminates the torque multiplication effect of the torque converter necessary for acceleration. Inputs that determine clutch engagement are: coolant temperature, vehicle speed and throttle position. The torque converter clutch is engaged by the clutch solenoid on the valve body. The clutch will engage at approximately 56 km/h (35 mph) with light throttle, after the shift to third gear. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 40TE Automatic Transaxle Torque Converter: Service and Repair 40TE Automatic Transaxle TORQUE CONVERTER REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. INSTALLATION Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate converter hub and oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale and straightedge (Fig. 301). Surface of converter lugs should be 1/2 inch to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5390 Torque Converter: Service and Repair 41TE Automatic Transmission 41TE - Automatic Transmission TORQUE CONVERTER REMOVAL 1. Remove transmission and torque converter from vehicle. 2. Place a suitable drain pan under the converter housing end of the transmission. CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. 3. Pull the torque converter forward until the center hub clears the oil pump seal. 4. Separate the torque converter from the transmission. INSTALLATION Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and notches with 320/400 grit paper or crocus cloth if necessary. The hub must be smooth to avoid damaging the pump seal at installation. 1. Lubricate converter hub and oil pump seal lip with transmission fluid. 2. Place torque converter in position on transmission. CAUTION: Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission. 3. Align torque converter to oil pump seal opening. 4. Insert torque converter hub into oil pump. 5. While pushing torque converter inward, rotate converter until converter is fully seated in the oil pump gears. 6. Check converter seating with a scale and straightedge (Fig. 335). Surface of converter lugs should be 1/2 inch to rear of straightedge when converter is fully seated. 7. If necessary, temporarily secure converter with C-clamp attached to the converter housing. 8. Install the transmission in the vehicle. 9. Fill the transmission with the recommended fluid. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Description and Operation Torque Converter Clutch: Description and Operation 41TE - Automatic Transmission DESCRIPTION TORQUE CONVERTER CLUTCH (TCC) The TCC (Fig. 332) was installed to improve the efficiency of the torque converter that is lost to the slippage of the fluid coupling. Although the fluid coupling provides smooth, shock-free power transfer, it is natural for all fluid couplings to slip. If the impeller and turbine were mechanically locked together, a zero slippage condition could be obtained. A hydraulic piston was added to the turbine, and a friction material was added to the inside of the front cover to provide this mechanical lock-up. OPERATION The converter impeller (Fig. 333) (driving member), which is integral to the converter housing and bolted to the engine drive plate, rotates at engine speed. The converter turbine (driven member), which reacts from fluid pressure generated by the impeller, rotates and turns the transmission input shaft. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Description and Operation > Page 5394 TURBINE As the fluid that was put into motion by the impeller blades strikes the blades of the turbine, some of the energy and rotational force is transferred into the turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine's blades it continues in a "hindering" direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR Torque multiplication is achieved by locking the stator's over-running clutch to its shaft (Fig. 334). Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counterclockwise direction. When this happens the over-running clutch of the stator locks and holds the stator from rotating. With the stator locked, the oil strikes the stator blades and is redirected into a "helping" direction before it enters the impeller. This circulation of oil from impeller to turbine, turbine to stator, and stator to impeller, can produce a maximum torque multiplication of about 2.4:1. As the turbine begins to match the speed of the impeller, the fluid that was hitting the stator in such as way as to cause it to lock-up is no longer doing so. In this condition of operation, the stator begins to free wheel and the converter acts as a fluid coupling. TORQUE CONVERTER CLUTCH (TCC) In a standard torque converter, the impeller and turbine are rotating at about the same speed and the stator is freewheeling, providing no torque multiplication. By applying the turbine's piston to the front cover's friction material, a total converter engagement can be obtained. The result of this engagement is a direct 1:1 mechanical link between the engine and the transmission. The engagement and disengagement of the TCC are automatic and controlled by the Powertrain Control Module (PCM). The engagement cannot be activated in the lower gears because it eliminates the torque multiplication effect of the torque converter necessary for acceleration. Inputs that determine clutch engagement are: coolant temperature, vehicle speed and throttle position. The torque converter clutch is engaged by the clutch solenoid on the valve body. The clutch will engage at approximately 56 km/h (35 mph) with light throttle, after the shift to third gear. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 5398 Transmission Control System Relay: Diagrams Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 5399 Transmission Control Relay (EATX) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Transmission Control System Relay: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION CONTROL RELAY - DESCRIPTION The transmission control relay (Fig. 336) is located in the Intelligent Power Module (IPM), which is located on the left side of the engine compartment between the battery and left fender. OPERATION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5402 Transmission Control System Relay: Description and Operation 40TE Automatic Transaxle TRANSMISSION CONTROL RELAY DESCRIPTION The transmission control relay (Fig. 302) is located in the Intelligent Power Module (IPM), which is located on the left side of the engine compartment between the battery and left fender. OPERATION The Transmission Control Relay is supplied fused B+ voltage, energized by the PCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the PCM energizes the relay. Prior to this, the PCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the PCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR Sensor, Transmission Range Sensor ...................................................................................................................................................... 5 Nm (45 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 5408 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5409 Transmission Range Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 337). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 338). OPERATION The Transmission Range Sensor (TRS) (Fig. 337) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5412 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 338) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5413 Transmission Position Switch/Sensor: Description and Operation 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 303). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM/TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 304). OPERATION The Transmission Range Sensor (TRS) (Fig. 303) communicates Shift Lever Position (SLP) to the PCM/TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the PCM/TCM receives from four sense circuits. The PCM/TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the PCM/TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5414 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 304) that the PCM/TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the PCM/TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the PCM/TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 5415 Transmission Position Switch/Sensor: Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle Transmission Position Switch/Sensor: Service and Repair 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 305). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 305) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5418 Transmission Position Switch/Sensor: Service and Repair 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 339). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 339) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5419 Transmission Position Switch/Sensor: Service and Repair 41TE REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 343). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 343) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications 41TE - Automatic Transmission Sensor, Input Speed ............................................................................................................................ .................................................... 27 Nm (20 ft. lbs.) Sensor, Output Speed ...................................... ........................................................................................................................................ 27 Nm (20 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 5428 Transmission Speed Sensor: Connector Locations Transmission Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 5429 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5430 Transmission Speed Sensor: Diagrams Input Speed Sensor Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle Transmission Speed Sensor: Description and Operation 40TE Automatic Transaxle Speed Sensor Input INPUT SPEED SENSOR DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case. The Input Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5433 The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as input shaft rpm. The PCM/TCM compares the input speed signal with output speed signal to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The PCM/TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Speed Sensor Output OUTPUT SPEED SENSOR DESCRIPTION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5434 The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case. The Output Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as output shaft rpm. The PCM/TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation Vehicle Speed Signal The vehicle speed signal is taken from the Output Speed Sensor. The PCM converts this signal into a pulse per mile and sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5435 Transmission Speed Sensor: Description and Operation 41TE Automatic Transmission Input Speed Sensor INPUT SPEED SENSOR DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case. The Input Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5436 The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as input shaft rpm. The PCM/TCM compares the input speed signal with output speed signal to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The PCM/TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Output Speed Sensor OUTPUT SPEED SENSOR DESCRIPTION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5437 The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case. The Output Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as output shaft rpm. The PCM/TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation Vehicle Speed Signal The vehicle speed signal is taken from the Output Speed Sensor. The PCM converts this signal into a pulse per mile and sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle Transmission Speed Sensor: Service and Repair 40TE Automatic Transaxle Input Speed Sensor SPEED SENSOR INPUT REMOVAL 1. Disconnect battery negative cable. 2. Disconnect input speed sensor connector (Fig. 284). 3. Unscrew and remove input speed sensor (Fig. 285). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5440 4. Inspect speed sensor o-ring (Fig. 286) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 286). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.) (Fig. 285). 3. Connect speed sensor connector (Fig. 284). 4. Connect battery negative cable. Output Speed Sensor SPEED SENSOR OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector (Fig. 290). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5441 4. Unscrew and remove output speed sensor (Fig. 291). 5. Inspect speed sensor o-ring (Fig. 292) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 292). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector (Fig. 290). 4. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5442 Transmission Speed Sensor: Service and Repair 41TE Automatic Transmission Input Speed Sensor SPEED SENSOR INPUT REMOVAL 1. Disconnect battery negative cable. 2. Disconnect input speed sensor connector (Fig. 284). 3. Unscrew and remove input speed sensor (Fig. 285). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5443 4. Inspect speed sensor o-ring (Fig. 286) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 286). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.) (Fig. 285). 3. Connect speed sensor connector (Fig. 284). 4. Connect battery negative cable. Output Speed Sensor SPEED SENSOR OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector (Fig. 290). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5444 4. Unscrew and remove output speed sensor (Fig. 291). 5. Inspect speed sensor o-ring (Fig. 292) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 292). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector (Fig. 290). 4. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 5448 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-008-04A > Oct > 04 > A/T - MIL ON/DTC P1776 Set Valve Body: Customer Interest A/T - MIL ON/DTC P1776 Set NUMBER: 21-008-04 REV. A GROUP: Transmission DATE: October 16, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-008-04, DATED JUNE 1, 2004. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL YEAR AND A UPDATED DISCUSSION. SUBJECT: MIL Illumination - DTC P1776 Solenoid Switch Valve Latched in LR Position MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2003 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - 2004 (KJ) Liberty 2003 - 2004 (KJ) Cherokee (International Markets) **2002** - 2004 (LH) 300M/Concorde/Intrepid 2003-2004 (PL) Neon/SX2.0 2003 - 2005 (PT) PT Cruiser 2003 - 2005 (RG) Chrysler Voyager (International Markets) 2003 - 2005 (RS) Town & Country/Voyager/Caravan 2003 - 2004 (TJ) Wrangler NOTE: Refer to the following table for specific applications. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-008-04A > Oct > 04 > A/T - MIL ON/DTC P1776 Set > Page 5457 DISCUSSION: If the vehicle operator describes a MIL illumination and the technician finds DTC P1776 Solenoid Switch Valve Latched in LR Position is set the DRBIII(R) can be used to access the event data screen and look at the "TRS Code" reading. NOTE: The solenoid switch valve is not in the solenoid pack it is in the valve body. TRS Code Reads TR2 If the TRS Code displays TR2 it is an indication that the manual valve was not fully in the OD position at the time the DTC was set. Check the shifter cable adjustment and adjust if necessary. Also check the shift control system for excessive friction and/or routing issues. TRS Code Reads OD If the "TRS Code displays "OD" then a sticky solenoid switch valve is the primary cause. Perform the proper diagnosis for the valve body. Inspect for foreign material in the solenoid switch valve and plugs. **FOR 2002 - 2004 LH MODEL ONLY** Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-008-04A > Oct > 04 > A/T - MIL ON/DTC P1776 Set > Page 5458 **If replacing the valve body assembly for DTC P1776 Solenoid Switch Valve Latched in LR Position first inspect the build date on the solenoid pack (Fig. 1) or (Fig. 2). If the build date range falls in between 3001 and 0603 replace the solenoid pack not the valve body** NOTE: The first three characters are the day of the year, the fourth character is the year, ie. 3001 is the 300th day of 2001. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-008-04A > Oct > 04 > A/T - MIL ON/DTC P1776 Set Valve Body: All Technical Service Bulletins A/T - MIL ON/DTC P1776 Set NUMBER: 21-008-04 REV. A GROUP: Transmission DATE: October 16, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-008-04, DATED JUNE 1, 2004. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL YEAR AND A UPDATED DISCUSSION. SUBJECT: MIL Illumination - DTC P1776 Solenoid Switch Valve Latched in LR Position MODELS: 2004 (AN) Dakota 2004 - 2005 (CS) Pacifica 2003 - 2004 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - 2004 (KJ) Liberty 2003 - 2004 (KJ) Cherokee (International Markets) **2002** - 2004 (LH) 300M/Concorde/Intrepid 2003-2004 (PL) Neon/SX2.0 2003 - 2005 (PT) PT Cruiser 2003 - 2005 (RG) Chrysler Voyager (International Markets) 2003 - 2005 (RS) Town & Country/Voyager/Caravan 2003 - 2004 (TJ) Wrangler NOTE: Refer to the following table for specific applications. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-008-04A > Oct > 04 > A/T - MIL ON/DTC P1776 Set > Page 5464 DISCUSSION: If the vehicle operator describes a MIL illumination and the technician finds DTC P1776 Solenoid Switch Valve Latched in LR Position is set the DRBIII(R) can be used to access the event data screen and look at the "TRS Code" reading. NOTE: The solenoid switch valve is not in the solenoid pack it is in the valve body. TRS Code Reads TR2 If the TRS Code displays TR2 it is an indication that the manual valve was not fully in the OD position at the time the DTC was set. Check the shifter cable adjustment and adjust if necessary. Also check the shift control system for excessive friction and/or routing issues. TRS Code Reads OD If the "TRS Code displays "OD" then a sticky solenoid switch valve is the primary cause. Perform the proper diagnosis for the valve body. Inspect for foreign material in the solenoid switch valve and plugs. **FOR 2002 - 2004 LH MODEL ONLY** Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 21-008-04A > Oct > 04 > A/T - MIL ON/DTC P1776 Set > Page 5465 **If replacing the valve body assembly for DTC P1776 Solenoid Switch Valve Latched in LR Position first inspect the build date on the solenoid pack (Fig. 1) or (Fig. 2). If the build date range falls in between 3001 and 0603 replace the solenoid pack not the valve body** NOTE: The first three characters are the day of the year, the fourth character is the year, ie. 3001 is the 300th day of 2001. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly Power Trunk / Liftgate Control Module: All Technical Service Bulletins Body - Power Liftgate Does Not Open/Close Properly NUMBER: 08-045-06 GROUP: Electrical DATE: October 17, 2006 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. WHILE THE FILES ARE CURRENTLY AVAILABLE FROM THE INTERNET FOR ALL MARKETS, FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE DRBIII(R) FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL ALSO BE AVAILABLE ON ITIL/ISIS DVD 4th QUARTER, 2006. SUBJECT: Flash: Power Liftgate May Not Open Or Close The First Time That The Power Liftgate Button Is Depressed OVERVIEW: This bulletin involves selectively erasing and reprogramming the Power Liftgate Module with new software. MODELS: 2002 - 2007 (RS/RG) Town & Country/Caravan/Voyager NOTE: This bulletin applies to vehicles equipped with a Power Liftgate (sales code JRC) built on or before October 13, 2006 (MDH 1013XX). SYMPTOM/CONDITION: The vehicle operator may describe that the Power Liftgate may not open or close the first time that the Power Liftgate button is depressed. If the button is pressed repeatedly, the liftgate will open or close properly. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII® connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE FOR DOMESTIC VEHICLES DOWNLOADING FLASH FILES FROM DealerCONNECT> Tech TOOLS: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly > Page 5471 NOTE Remove any unnecessary PCMCIA cards prior to starting a DRBIII(R) flash. 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the Power Liftgate Module currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2007 Diagnostics". c. "All (Except Below)". d. "Body Interior". e. "Doors, Gates & Comfort". f. "Power Lift Module". g. "Module Display". h. Record the "Power Liftgate Module part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "Power Liftgate Module part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the '~Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to next step. NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly > Page 5472 Due to the Power Liftgate Module programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly > Page 5478 NOTE Remove any unnecessary PCMCIA cards prior to starting a DRBIII(R) flash. 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the Power Liftgate Module currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2007 Diagnostics". c. "All (Except Below)". d. "Body Interior". e. "Doors, Gates & Comfort". f. "Power Lift Module". g. "Module Display". h. Record the "Power Liftgate Module part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "Power Liftgate Module part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the '~Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to next step. NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly > Page 5479 Due to the Power Liftgate Module programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 5480 Valve Body: Specifications 41TE - Automatic Transmission Bolt, Valve Body-to-Case .................................................................................................................... ............................................. 12 Nm (105 inch lbs.) Screw, Valve Body-to-Transfer Plate .................................................................................................................................................... 5 Nm (45 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle Valve Body: Description and Operation 40TE Automatic Transaxle VALVE BODY DESCRIPTION The valve body assembly consists of a cast aluminum valve body, a separator plate, and transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch, solenoid/pressure switch assembly, and frictional clutches. The valve body contains the following components (Fig. 306): ^ Regulator valve ^ Solenoid switch valve ^ Manual valve ^ Converter clutch switch valve ^ Converter clutch control valve ^ Torque converter regulator valve ^ Low/Reverse switch valve In addition, the valve body also contains the thermal valve, #2, 3 & 4 check balls, the #5 (overdrive) check valve and the 2/4 accumulator assembly. OPERATION NOTE: Refer to the Hydraulic Schematics for a visual aid in determining valve location, operation and design. REGULATOR VALVE The regulator valve controls hydraulic pressure in the transaxle. It receives unregulated pressure from the pump, which works against spring tension to maintain oil at specific pressures. A system of sleeves and ports allows the regulator valve to work at one of three predetermined pressure levels. Regulated oil pressure is also referred to as "line pressure." SOLENOID SWITCH VALVE The solenoid switch valve controls line pressure from the LR/CC solenoid. In one position, it allows the low/reverse clutch to be pressurized. In the other, it directs line pressure to the converter control and converter clutch valves. MANUAL VALVE The manual valve is operated by the mechanical shift linkage. Its primary responsibility is to send line pressure to the appropriate hydraulic circuits and solenoids. The valve has three operating ranges or positions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5483 CONVERTER CLUTCH SWITCH VALVE The main responsibility of the converter clutch switch valve is to control hydraulic pressure applied to the front (off) side of the converter clutch piston. Line pressure from the regulator valve is fed to the torque converter regulator valve, where it passes through the valve, and is slightly regulated. The pressure is then directed to the converter clutch switch valve and to the front side of the converter clutch piston. This pressure pushes the piston back and disengages the converter clutch. CONVERTER CLUTCH CONTROL VALVE The converter clutch control valve controls the back (on) side of the torque converter clutch. When the PCM/TCM energizes or modulates the LR/CC solenoid to apply the converter clutch piston, both the converter clutch control valve and the converter control valve move, allowing pressure to be applied to the back side of the clutch. T/C REGULATOR VALVE The torque converter regulator valve slightly regulates the flow of fluid to the torque converter. LOW/REVERSE SWITCH VALVE The low/reverse clutch is applied from different sources, depending on whether low (1st) gear or reverse is selected. The low/reverse switch valve alternates positions depending on from which direction fluid pressure is applied. By design, when the valve is shifted by fluid pressure from one channel, the opposing channel is blocked. The switch valve alienates the possibility of a sticking ball check, thus providing consistent application of the low/reverse clutch under all operating conditions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5484 Valve Body: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission VALVE BODY - DESCRIPTION DESCRIPTION The valve body assembly consists of a cast aluminum valve body, a separator plate, and transfer plate. The valve body contains valves and check balls that control fluid delivery to the torque converter clutch, solenoid/pressure switch assembly, and frictional clutches. The valve body contains the following components (Fig. 340): - Regulator valve - Solenoid switch valve - Manual valve - Converter clutch switch valve - Converter clutch control valve - Torque converter regulator valve - Low/Reverse switch valve In addition, the valve body also contains the thermal valve, #2, 3&4 check balls, the #5 (overdrive) check valve and the 2/4 accumulator assembly. OPERATION NOTE: Refer to the Hydraulic Schematics for a visual aid in determining valve location, operation and design. REGULATOR VALVE The regulator valve controls hydraulic pressure in the transaxle. It receives unregulated pressure from the pump, which works against spring tension to maintain oil at specific pressures. A system of sleeves and ports allows the regulator valve to work at one of three predetermined pressure levels. Regulated oil pressure is also referred to as "line pressure." SOLENOID SWITCH VALVE The solenoid switch valve controls line pressure from the LR/CC solenoid. In one position, it allows the low/reverse clutch to be pressurized. In the other, it directs line pressure to the converter control and converter clutch valves. MANUAL VALVE The manual valve is operated by the mechanical shift linkage. Its primary responsibility is to send line pressure to the appropriate hydraulic circuits and solenoids. The valve has three operating ranges or positions. CONVERTER CLUTCH SWITCH VALVE The main responsibility of the converter clutch switch valve is to control hydraulic pressure applied to the front (off) side of the converter clutch piston. Line pressure from the regulator valve is fed to the torque converter regulator valve, where it passes through the valve, and is slightly regulated. The pressure is then directed to the converter clutch switch valve and to the front side of the converter clutch piston. This pressure pushes the piston back and disengages the converter clutch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5485 CONVERTER CLUTCH CONTROL VALVE The converter clutch control valve controls the back (on) side of the torque converter clutch. When the TCM energizes or modulates the LR/CC solenoid to apply the converter clutch piston, both the converter clutch control valve and the converter control valve move, allowing pressure to be applied to the back side of the clutch. T/C REGULATOR VALVE The torque converter regulator valve slightly regulates the flow of fluid to the torque converter. LOW/REVERSE SWITCH VALVE The low/reverse clutch is applied from different sources, depending on whether low (1st) gear or reverse is selected. The low/reverse switch valve alternates positions depending on from which direction fluid pressure is applied. By design, when the valve is shifted by fluid pressure from one channel, the opposing channel is blocked. The switch valve alienates the possibility of a sticking ball check, thus providing consistent application of the low/reverse clutch under all operating conditions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle Valve Body: Service and Repair 40TE Automatic Transaxle Removal VALVE BODY REMOVAL NOTE: If valve body is replaced or reconditioned, the TCM Quick Learn Procedure must be performed. 1. Disconnect battery negative cable. 2. Disconnect gearshift cable from manual valve lever. 3. Remove manual valve lever from manual shaft. 4. Raise vehicle on hoist. 5. Remove oil pan bolts (Fig. 307). 6. Remove oil pan (Fig. 308). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5488 7. Remove oil filter (Fig. 309). 8. Remove the valve body-to-transaxle case bolts (Fig. 310). NOTE: To ease removal of the valve body, turn the manual valve lever fully clockwise to low or first gear. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5489 9. Remove park rod rollers from guide bracket and remove valve body from transaxle (Fig. 311) (Fig. 312). CAUTION: The valve body manual shaft pilot may distort and bind the manual valve if the valve body is mishandled or dropped. Disassembly VALVE BODY DISASSEMBLY NOTE: If valve body assembly is being reconditioned, the PCM/TCM Quick Learn Procedure must be performed. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5490 1. Remove manual shaft seal (Fig. 313). 2. Remove Transmission Range Sensor retaining screw (Fig. 314). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5491 3. Remove Manual Shaft/Rooster Comb and Transmission Range Sensor (Fig. 315). 4. Remove 2/4 Accumulator Retaining Plate (Fig. 316). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5492 5. Remove 2/4 Accumulator components as shown in (Fig. 317). 6. Remove Valve Body to Transfer Plate screws (Fig. 318). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5493 7. Invert assembly and remove Transfer Plate (Fig. 319). Beware of loose check balls. 8. Remove oil screen (Fig. 320). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5494 9. Remove the overdrive clutch (#5) check valve (Fig. 321) 10. Remove separator plate (Fig. 322). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5495 11. Remove thermal valve (Fig. 323). 12. Remove check balls (Fig. 324). NOTE: Tag all valve/spring assemblies for reassembly identification. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5496 13. Remove dual retainer plate using Tool 6301 (Fig. 325). 14. Remove regulator valve spring retainer (Fig. 326). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5497 15. Remove remaining retainers as shown in (Fig. 327). 16. Remove valves and springs as shown in (Fig. 328). NOTE: Refer to Valve Body Cleaning and Inspection for cleaning procedures. Assembly VALVE BODY ASSEMBLY NOTE: If valve body assembly is reconditioned, the PCM/TCM Quick Learn Procedure must be performed. 1. Install valves and springs as shown in (Fig. 328). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5498 2. Install regulator valve spring retainer (Fig. 329). 3. Install dual retainer plate using Tool 6301 (Fig. 330). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5499 4. Verify that all retainers are installed as shown in (Fig. 331). Retainers should be flush or below valve body surface. 5. Install check balls into position as shown in (Fig. 332). If necessary, secure them with petrolatum or transmission assembly gel for assembly ease. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5500 6. Install thermal valve into transfer plate (Fig. 333). 7. Install separator plate to valve body (Fig. 334). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5501 8. Install the overdrive clutch (#5) check valve to separator plate (Fig. 335) 9. Install oil screen to separator plate (Fig. 336). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5502 10. Install transfer plate to valve body and separator plate. Make sure oil screen and #5 check valve do not bind (Fig. 337). 11. Install twenty-four transfer plate to valve body screws (Fig. 338) and torque to 5 Nm (45 inch lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5503 12. Install 2/4 Accumulator components as shown in (Fig. 339). 13. Torque 2/4 Accumulator retainer to 5 Nm (45 inch lbs.) (Fig. 340). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5504 14. Install Manual Shaft/Rooster Comb and Transmission Range Sensor (Fig. 341). 15. Make sure Manual Valve control pin is contained within the rooster comb slot (Fig. 342). Install Transmission Range Sensor retaining screw (Fig. 342) and torque to 5 Nm (45 inch lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5505 16. Install manual shaft seal (Fig. 343). Installation VALVE BODY INSTALLATION NOTE: If valve body assembly is being replaced or reconditioned, it is necessary to perform the TCM Quick Learn Procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5506 1. Install valve body assembly to transaxle (Fig. 344). Install and torque valve body-to-transaxle case bolts (Fig. 345) to 12 Nm (105 inch lbs.). 2. Install transaxle oil filter (Fig. 346). Inspect the o-ring and replace if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5507 3. Ensure the transaxle oil pan and transaxle case sealing surfaces are clean and dry. Install an 1/8" bead of Mopar Silicone Rubber Adhesive Sealant to the oil pan and install (Fig. 347). Torque oil pan-to-transaxle case bolts (Fig. 348) to 19 Nm (165 inch lbs.). 4. Lower vehicle. 5. Connect transmission range sensor connector. 6. Install manual valve lever to manual shaft. 7. Install gearshift cable to manual valve lever. 8. Connect battery negative cable. 9. Fill transaxle with Mopar ATF +4 Transmission fluid. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5508 Valve Body: Service and Repair 41TE Automatic Transaxle Removal REMOVAL NOTE: If valve body is replaced or reconditioned, the TCM Quick Learn Procedure must be performed. 1. Disconnect battery negative cable. 2. Disconnect gearshift cable from manual valve lever. 3. Remove manual valve lever from manual shaft. 4. Raise vehicle on hoist. 5. Remove oil pan bolts (Fig. 148). 6. Remove oil pan (Fig. 149). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5509 7. Remove oil filter (Fig. 150). 8. Remove the valve body-to-transaxle case bolts (Fig. 151). NOTE: To ease removal of the valve body, turn the manual valve lever fully clockwise to low or first gear. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5510 9. Remove park rod rollers from guide bracket and remove valve body from transaxle (Fig. 152) (Fig. 153). CAUTION: The valve body manual shaft pilot may distort and bind the manual valve if the valve body is mishandled or dropped. Disassembly VALVE BODY DISASSEMBLY NOTE: If valve body assembly is being reconditioned, the PCM/TCM Quick Learn Procedure must be performed. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5511 1. Remove manual shaft seal (Fig. 154). 2. Remove Transmission Range Sensor retaining screw (Fig. 155). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5512 3. Remove Manual Shaft/Rooster Comb and Transmission Range Sensor (Fig. 156). 4. Remove 2/4 Accumulator Retaining Plate (Fig. 157). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5513 5. Remove 2/4 Accumulator components as shown in (Fig. 158). 6. Remove Valve Body to Transfer Plate screws (Fig. 159). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5514 7. Invert assembly and remove Transfer Plate (Fig. 160). Beware of loose check balls. 8. Remove oil screen (Fig. 161). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5515 9. Remove the overdrive clutch (#5) check valve (Fig. 162) 10. Remove separator plate (Fig. 163). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5516 11. Remove thermal valve (Fig. 164). 12. Remove check balls (Fig. 165). NOTE: Tag all valve/spring assemblies for reassembly identification. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5517 13. Remove dual retainer plate using Tool 6301 (Fig. 166). 14. Remove regulator valve spring retainer (Fig. 167). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5518 15. Remove remaining retainers as shown in (Fig. 168). 16. Remove valves and springs as shown in (Fig. 169). NOTE: Refer to Valve Body Cleaning and Inspection for cleaning procedures. Assembly VALVE BODY ASSEMBLY NOTE: If valve body assembly is reconditioned, the PCM/TCM Quick Learn Procedure must be performed. 1. Install valves and springs as shown in (Fig. 169). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5519 2. Install regulator valve spring retainer (Fig. 170). 3. Install dual retainer plate using Tool 6301 (Fig. 171). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5520 4. Verify that all retainers are installed as shown in (Fig. 172). Retainers should be flush or below valve body surface. 5. Install check balls into position as shown in (Fig. 173). If necessary, secure them with petrolatum or transmission assembly gel for assembly ease. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5521 6. Install thermal valve into transfer plate (Fig. 174). 7. Install separator plate to valve body (Fig. 175). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5522 8. Install the overdrive clutch (#5) check valve to separator plate (Fig. 176) 9. Install oil screen to separator plate (Fig. 177). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5523 10. Install transfer plate to valve body and separator plate. Make sure oil screen and #5 check valve do not bind (Fig. 178). 11. Install twenty-four transfer plate to valve body screws (Fig. 179) and torque to 5 Nm (45 inch lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5524 12. Install 2/4 Accumulator components as shown in (Fig. 180). 13. Torque 2/4 Accumulator retainer to 5 Nm (45 inch lbs.) (Fig. 181). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5525 14. Install Manual Shaft/Rooster Comb and Transmission Range Sensor (Fig. 182). 15. Make sure Manual Valve control pin is contained within the rooster comb slot (Fig. 183). Install Transmission Range Sensor retaining screw (Fig. 183) and torque to 5 Nm (45 inch lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5526 16. Install manual shaft seal (Fig. 184). Installation VALVE BODY INSTALLATION NOTE: If valve body assembly is being replaced or reconditioned, it is necessary to perform the TCM Quick Learn Procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5527 1. Install valve body assembly to transaxle (Fig. 185). Install and torque valve body-to-transaxle case bolts (Fig. 186) to 12 Nm (105 inch lbs.). 2. Install transaxle oil filter (Fig. 187). Inspect the o-ring and replace if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5528 3. Ensure the transaxle oil pan and transaxle case sealing surfaces are clean and dry. Install an 1/8" bead of Mopar Silicone Rubber Adhesive Sealant to the oil pan and install (Fig. 188). Torque oil pan-to-transaxle case bolts (Fig. 189) to 19 Nm (165 inch lbs.). 4. Lower vehicle. 5. Connect transmission range sensor connector. 6. Install manual valve lever to manual shaft. 7. Install gearshift cable to manual valve lever. 8. Connect battery negative cable. 9. Fill transaxle with Mopar ATF +4 Transmission fluid. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5535 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations Right Side Kick Panel RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5545 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5550 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Component Information > Description and Operation Differential Carrier: Description and Operation DIFFERENTIAL ASSEMBLY DESCRIPTION The differential gear system divides the torque between the axle shafts. It allows the axle shafts to rotate at different speeds when turning corners. Each differential side gear is splined to an axle shaft. The pinion gears are mounted on a pinion mate shaft and are free to rotate on the shaft. The pinion gear is fitted in a bore in the differential case and is positioned at a right angle to the axle shafts. OPERATION In operation, power flow occurs as follows: The pinion gear rotates the ring gear - The ring gear (bolted to the differential case) rotates the case - The differential pinion gears (mounted on the pinion mate shaft in the case) rotate the side gears - The side gears (splined to the axle shafts) rotate the shafts During straight-ahead driving, the differential pinion gears do not rotate on the pinion mate shaft. This occurs because input torque applied to the gears is divided and distributed equally between the two side gears. As a result, the pinion gears revolve with the pinion mate shaft but do not rotate around it (Fig. 38). When turning corners, the outside wheel must travel a greater distance than the inside wheel to complete a turn. The difference must be compensated for to prevent the tires from scuffing and skidding through turns. To accomplish this, the differential allows the axle shafts to turn at unequal speeds (Fig. 39). In this instance, the input torque applied to the pinion gears is not divided equally. The pinion gears now rotate around the pinion mate shaft in opposite directions. This allows the side gear and axle shaft attached to the outside wheel to rotate at a faster speed. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Specifications Differential Clutch: Specifications Bolt, Overrunning Clutch Housing-to-Differential ................................................................................................................................... 60 Nm (44 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Specifications > Page 5558 Differential Clutch: Description and Operation BI DIRECTIONAL OVERRUNNING CLUTCH DESCRIPTION The Bi-Directional Overrunning Clutch (BOC) (Fig. 28) works as a mechanical disconnect between the front and rear axles, preventing torque from being transferred from the rear axle to the front. The BOC is a simply an overrunning clutch which works in both clockwise and counter-clockwise rotations. This means that when the output (the rear axle) is rotating faster in one direction than the input (front axle), there is no torque transmission. But when the input speed is equal to the output speed, the unit becomes locked. The BOC provides significant benefits regarding braking stability, handling, and driveline durability. Disconnecting the front and the rear driveline during braking helps to maintain the braking stability of an AWD vehicle. In an ABS/braking event, the locking of the rear wheels must be avoided for stability reasons. Therefore brake systems are designed to lock the front wheels first. Any torque transfer from the rear axle to the front axle disturbs the ABS/braking system and causes potential instabilities on a slippery surface. The BOC de-couples the rear driveline as soon the rear wheels begin to spin faster than the front wheels (front wheels locked) in order to provide increased braking stability. Furthermore the BOC also reduces the likelihood of throttle off over-steer during cornering. In a throttle off maneuver, the BOC once again de-couples the rear driveline forcing all the engine brake torque to the front wheels. This eliminates the chance of lateral slip on the rear axle and increases it on the front. The vehicle will therefore tend to understeer, a situation, which is considered easier to manage in most circumstances. During this maneuver, and during the ABS braking event, the BOC does not transmit torque through to the rear wheels. The rear driveline module, with the BOC, will perform the same as a front wheel drive vehicle during these events. The gear ratio offset between the front and rear differentials force the BOC into the overrunning mode most of the time. This allows BOC to significantly reduce the rolling resistance of the vehicle, which improves fuel consumption, allows the downsizing of the driveline components, and prevents the PTU and propshaft joints from overheating. OPERATION In order to achieve all-wheel drive operation in reverse, the overrunning clutch locking functional direction must be reversible. The Bi-Directional Overrunning Clutch (BOC) changes the operational mode direction depending on the propeller shaft direction. The propeller shaft rotates in the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Specifications > Page 5559 clockwise (when viewed from the front) direction when the vehicle is moving forward, which indexes the BOC to the forward overrunning position. When the vehicle is in reverse, the propeller shaft will rotate counter-clockwise and index the BOC to the reverse overrunning position. The BOC acts as a mechanical stator. It is active (transmitting torque), or it is not active and in overrunning mode (not transmitting torque). This "all or nothing" approach to torque transfer would cause a sudden application of all available power to the rear wheels, which is not desirable. Therefore it is run in series with a viscous coupler to smooth, dampen, and limit the transmission of torque to the rear axle and to prevent a step style torque input to the rear axle. STEADY STATE, LOW TO MODERATE SPEED, NO FRONT WHEEL SLIP, FORWARD DIRECTION During normal driving conditions, (no wheel slip), the inner shaft (front axle) and outer race (viscous coupler) are running at different speeds due to the different gear ratios between the front and rear differentials. In this condition, the outer race is always spinning faster (overdriving between 5 - 32 rpm) than the inner shaft. When the BOC (Fig. 29) is running under these conditions, at low vehicle speeds the drag shoes and the cage keep the rollers up on the left side (forward side) of the inner shaft flats. This is what is known as "overrunning mode." Notice that when the clutch is in overrunning mode, the rollers are spinning clockwise and with the outer race, thus no torque is being transferred. NOTE: Low speed, forward and reverse operation is identical, just in opposite directions. (Fig. 29) shows forward direction in reverse the rollers are on the other side of the flats due to a reversal of the cage force. TRANSIENT CONDITION (BOC LOCKED), FRONT WHEEL SLIP, FORWARD DIRECTION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Specifications > Page 5560 When the front wheels lose traction and begin to slip, the propeller shaft and rear axle pinion speed difference decreases to zero. At this point the input shaft (cam) becomes the driving member of the BOC (Fig. 30), compressing the rollers against the outer race. This locks the input shaft with the outer race and transmits torque to the housing of the viscous coupler, that in turn transmits torque to the rear axle pinion. It should also be noted that when the device is locked, the inner shaft and the outer race are rotating at the same speed. The rollers are pinched at this point and will stay locked until a torque reversal (no front wheel slip) occurs. When locked, the viscous coupler slips during the torque transfer and the amount of torque transferred is dependent on the coupling characteristic and the amount of front wheel slip. STEADY STATE, HIGH SPEED, NO WHEEL SLIP The roller cage positions the rollers on the input shaft flats during low and high speed overrunning and during initial BOC lockup. The roller cage is rotating at input shaft (propeller shaft) speed at all times. At low speeds, the friction shoes (Fig. 31) are pressed against the friction ground via the garter spring (Fig. 32), creating a drag force on the roller cage. The drag force positions the cage, which in turn positions the rollers to one side of the flat. The direction of this drag force (position of the roller) is dependent on the input (propeller shaft) rotational direction. Since the rollers are always in contact with the outer race, due to centrifugal forces, the rollers want to follow the outer race due to drag. During overrunning operation, the outer race is rotating faster than the input; causing the rollers to want to traverse the flat from one side to the other. During low speeds, the brake shoes counteract this effect. To avoid excessive wear, the ground shoes are designed to lift off from the friction ground due to centrifugal forces at higher rotational speeds. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Specifications > Page 5561 To keep the rollers in the overrunning position and avoid undesired "high speed lockup", a high speed latch (Fig. 33) positions the cage before the ground shoes lift off. A further explanation of the high speed effects follows as well. Utilizing only the friction shoes approach means that at high speed the required ground shoe drag torque would cause excessive brake shoe wear or the roller will begin to migrate to the opposite side of the flat due to the drag force of the outer race. This would result in system lock-up. (Fig. 34) shows the BOC as it crosses the speed where the brake shoe force is overcome by the roller drag on the outer race. Notice that the roller is locking up on the opposite side of the flat and the cage supplies no force on the rollers. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Specifications > Page 5562 This lock-up is not desired, and requires the use of another mechanism to prevent the lock-up. The device that prevents undesired high-speed lock-up is called a "high speed latch". Similar to the friction shoes, the two-piece high speed latch will separate from each other at high rotational speeds due to centrifugal effects. (Fig. 35) shows the high speed latch engaged. The gap "x" increases with speed, eventually locking into one of the slots in the BOC shaft. When the high-speed latch is activated (propeller shaft speed reaches X amount), the cage is partially fixed, and cannot lock on the wrong side of the flat as shown (Fig. 34). The high speed latch is a one way device and does not prevent high-speed lockup in the reverse direction. At high speeds, the BOC provides the same function as low speeds, transferring torque to the viscous coupler only when front wheel slip overcomes the axle ratio offset. At high speed, the rollers are forced outward to the outer race because of centrifugal force. At high speeds, the friction shoes can no longer prevent lockup. When the teeth on the high-speed latch engage into the input shaft, it keeps the rollers centered above the flats because the tabs on the latch are locked into the cage. (Fig. 36) shows the roller configuration with the High-Speed Latch engaged. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Specifications > Page 5563 On the BOC shaft, the high speed latch teeth lock up in the grooved areas, shown in (Fig. 37), when the turning speed reaches the critical value. (Fig. 37) also shows the outer race/viscous coupler. Notice the surface (outer race) the rollers mate against when transferring torque. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5568 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Differential DIFFERENTIAL ASSEMBLY FLUID The correct fill level is to the bottom of the fill plug hole. Be sure the vehicle is on a level surface, or is hoisted in a level manner, in order to obtain the correct fill level. Drain & Fill Using a suction gun or equivalent, fill the differential assembly with 0.7 Liters (1.48 Pt) Overrunning Clutch OVERRUNNING CLUTCH HOUSING FLUID Drain & Fill Using a suction gun add 0.58 Liters (1.22 Pt) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 5571 Fluid - Differential: Fluid Type Specifications Differential DIFFERENTIAL ASSEMBLY FLUID Checking Fluid The correct fill level is to the bottom of the fill plug hole. Be sure the vehicle is on a level surface, or is hoisted in a level manner, in order to obtain the correct fill level. Drain & Fill Using a suction gun or equivalent, fill the differential assembly with 0.7 L (1.48 Pt) Lubricant ...................................................................................................................................................... Mopar SAE 80W-90 Gear and Axle Lubricant Overrunning Clutch OVERRUNNING CLUTCH HOUSING FLUID Drain & Fill Using a suction gun add 0.58 L (1.22 Pt) Lubricant ................................................................................................................................ Mopar ATF+4 (Automatic Transmission Fluid - Type 9602) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Differential Assembly Fluid Drain and Fill Fluid - Differential: Service and Repair Differential Assembly Fluid Drain and Fill STANDARD PROCEDURE - DIFFERENTIAL ASSEMBLY FLUID DRAIN AND FILL The drain plug (Fig. 40) for the differential assembly is located in the bottom of the differential assembly case, toward the rear of the unit. The fill plug (Fig. 41) for the differential assembly is located on the rear of the assembly case. The correct fill level is to the bottom of the fill plug hole. Be sure the vehicle is on a level surface, or is hoisted in a level manner, in order to obtain the correct fill level. 1. Raise the vehicle on a hoist. 2. Position a drain pan under the differential drain plug (Fig. 40). 3. Remove the drain plug and allow the fluid to drain into the pan. 4. Install the drain plug and torque to 35 Nm (26 ft. lbs.). 5. Re-position the drain pan under the differential fill plug. 6. Remove the differential fill plug (Fig. 41). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Differential Assembly Fluid Drain and Fill > Page 5574 7. Using a suction gun (Fig. 42) or equivalent, fill the differential assembly with 0.7 Liters (1.48 pints) of Mopar Gear and Axle Lubricant (80W-90). 8. Install the fill plug and torque to 35 Nm (26 ft. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Differential Assembly Fluid Drain and Fill > Page 5575 Fluid - Differential: Service and Repair Overrunning Clutch Housing Fluid Change STANDARD PROCEDURE - OVERRUNNING CLUTCH HOUSING FLUID CHANGE 1. Raise vehicle on hoist. 2. Position a drain pan under overrunning clutch housing drain plug. 3. Remove overrunning clutch housing drain plug and drain fluid (Fig. 43). 4. Install the drain plug and torque to 30 Nm (22 ft. lbs.). 5. Re-position the drain pan under the overrunning clutch housing fill plug. 6. Remove fill plug (Fig. 44). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Service and Repair > Differential Assembly Fluid Drain and Fill > Page 5576 7. Using a suction gun (Fig. 45), add 0.58 Liters (1.22 pints) of Mopar ATF+4 (Automatic Transmission Fluid-Type 9602). 8. Install fill plug and torque to 30 Nm (22 ft. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Input Flange Seal Seals and Gaskets: Service and Repair Input Flange Seal INPUT FLANGE SEAL REMOVAL 1. Raise vehicle on hoist. 2. Remove propeller shaft. 3. Using tool 6958, remove input flange nut and washer (Fig. 48). 4. Remove input flange (Fig. 49). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Input Flange Seal > Page 5581 5. Using suitable screwdriver, remove input flange seal from overrunning clutch housing (Fig. 50). INSTALLATION 1. Using tool 8802, install input flange seal to overrunning clutch case (Fig. 51). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Input Flange Seal > Page 5582 2. Install input flange (Fig. 52). 3. Install flange nut and washer. Using tool 6958, torque flange nut to 135 Nm (100 ft. lbs.) (Fig. 53). 4. Install propeller shaft. 5. Lower vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Input Flange Seal > Page 5583 Seals and Gaskets: Service and Repair Output Flange Seal OUTPUT FLANGE SEAL REMOVAL 1. Raise vehicle on hoist. 2. Remove rear halfshaft inner joint at differential output flange (Fig. 54). 3. Using two screwdrivers and wood blocks to protect differential housing casting, pry output flange out of differential (Fig. 55). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Input Flange Seal > Page 5584 4. Use suitable screwdriver to remove output flange seal (Fig. 56). INSTALLATION 1. Install output flange seal to differential housing using tool C4171A and 8493 (Fig. 57). 2. Install output flange to differential assembly. Verify that it is seated all the way into position by attempting to pull out by hand. 3. Install rear halfshaft inner joint to output flange. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Input Flange Seal > Page 5585 4. Install and torque bolts to 61 Nm (45 ft. lbs.) (Fig. 58). 5. Check differential assembly fluid level and adjust as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Viscous Coupling, Differential > Component Information > Description and Operation Viscous Coupling: Description and Operation DESCRIPTION The heart of the all-wheel drive system is the inter-axle viscous coupling and bi-directional overrunning clutch. Under normal driving the vehicle retains predominantly front wheel drive characteristics. The all-wheel drive takes effect when the front wheels start to slip. Under normal level road, straight line driving, 100% of the torque is allocated to the front wheels. The viscous coupler allows more torque to the rear wheels in accordance with the amount of slippage at the front wheels. The variable torque distribution is automatic with no driver inputs required. OPERATION The viscous coupler (Fig. 46) is a housing nearly filled with a high viscosity silicone liquid and thin metal plates alternately splined to an inner and outer drum. The viscous coupler provides torque in the following modes: - Shear mode (normal operation) - Hump mode (locked mode) The inner plates are slotted around the radius and the outer plates have holes in them. In the shear mode (normal operation), the plates are evenly spaced and the torque is created by the shearing of the plates through the fluid and 90-100% of the torque is applied to the rear axle. During the shear mode, a fluid flow pattern is created from this design (holes and slots). This fluid flow causes high pressure on each side of each pair of plates and low pressure between each pair of plates. When a high speed difference (shear) occurs because of loss of traction (one axle spinning faster than the other), the silicone fluid expands as it heats from this shearing. When the silicone expands to fill the viscous coupler completely, this pressure difference is high enough to squeeze each pair of plates together. The resulting hump torque is up to 8 times higher than the shear torque. When the viscous coupler is in the hump mode, it does not lock the axles (undifferentiated 4-Wheel Drive). It controls the amount of slippage while delivering maximum power to the axle having greatest traction. Once the speed difference equalizes the fluid and plates cool down and the viscous coupler goes back to the shear mode. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation - Front Axle Half Shaft Axle Shaft: Service and Repair Removal and Installation - Front Axle Half Shaft REMOVAL 1. Raise vehicle. 2. Remove the cotter pin and nut lock (Fig. 2) from the end of the half shaft. 3. Remove the wheel and tire assembly from the vehicle. 4. Remove the wave washer (Fig. 3) from the end of the half shaft. 5. With the vehicle's brakes applied to keep hub from turning, loosen and remove the half shaft nut. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation - Front Axle Half Shaft > Page 5595 6. Remove the two front disc brake caliper adapter to steering knuckle attaching bolts (Fig. 4). 7. Remove the disc brake caliper assembly from the steering knuckle. Caliper assembly is removed by first rotating top of caliper assembly away from steering knuckle and then removing bottom of assembly out from under machined abutment on steering knuckle. 8. Support disc brake caliper assembly by using a wire hook and suspending it from the strut assembly (Fig. 5). Do not allow the brake caliper assembly to hang by the brake flex hose. 9. Remove the brake rotor from the hub and bearing assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation - Front Axle Half Shaft > Page 5596 10. Remove the steering knuckle-to-strut attachment bolts (Fig. 6) from the steering knuckle. 11. Pull the steering knuckle from the strut clevis bracket. NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow half shaft to hang by inner C/V joint after removing outer C/V Joint from the hub/bearing assembly in steering knuckle, end of half shaft must be supported. 12. Pull steering knuckle assembly down and away from the outer C/V joint of the half shaft assembly while pulling the joint out of the hub bearing. 13. Support the outer end of the half shaft assembly. Insert a pry bar between inner tripod joint and transaxle case (Fig. 7). Pry against inner tripod joint, until tripod joint retaining snap-ring is disengaged from transaxle side gear. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation - Front Axle Half Shaft > Page 5597 14. Hold inner tripod joint and interconnecting shaft of half shaft assembly. Remove inner tripod joint from transaxle, by pulling it straight out of transaxle side gear and transaxle oil seal (Fig. 8). When removing tripod joint, do not let spline or snap-ring drag across sealing lip of the transaxle to tripod joint oil seal. INSTALLATION 1. Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant. 2. Holding half shaft assembly by tripod joint and interconnecting shaft, install tripod joint into transaxle side gear as far as possible by hand (Fig. 8). 3. Grasp inner tripod joint an interconnecting shaft. Forcefully push the tripod joint into side gear of transaxle, until snap-ring is engaged with transaxle side gear. Test that snap-ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand. If snap-ring is fully engaged with side gear, tripod joint will not be removable by hand. 4. Clean all debris and moisture out of steering knuckle, in the area were outer CV joint will be installed into steering knuckle. 5. Ensure that front of outer CV joint which fits against the face of the hub and bearing is free of debris and moisture before installing outer CV joint into hub and bearing assembly (Fig. 9). 6. Slide half shaft back into front hub and bearing assembly. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation - Front Axle Half Shaft > Page 5598 CAUTION: If the vehicle being serviced is equipped with eccentric strut assembly attaching bolts, the eccentric bolt must be installed in the bottom (slotted) hole on the strut clevis bracket (Fig. 10). 7. Install steering knuckle in clevis bracket of strut damper assembly. Install the strut damper to steering knuckle attaching bolts. Tighten both bolts to a torque of 81 Nm (60 ft. lbs.) plus an additional 1/4 turn. 8. Install braking disc on hub and bearing assembly. 9. Install disc brake caliper assembly on steering knuckle. Caliper is installed, by first sliding bottom of caliper assembly under abutment on steering knuckle, and then rotating top of caliper against top abutment. 10. Install disc brake caliper adapter to steering knuckle attaching bolts (Fig. 4). Tighten the disc brake caliper adapter attaching bolts to a torque of 169 Nm (125 ft. lbs.). 11. Clean all foreign matter from the threads of the outer CV joint. Install the washer and half shaft to hub/bearing assembly nut on half shaft and securely tighten nut. 12. Install front wheel and tire assembly. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the required specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 13. Lower vehicle. 14. With the vehicle's brakes applied to keep hub from turning, tighten the hub nut to a torque of 244 Nm (180 ft. lbs.) (Fig. 11). 15. Install the spring wave washer on the end of the half shaft. 16. Install the hub nut lock, and a new cotter pin (Fig. 2). Wrap cotter pin prongs tightly around the hub nut lock as shown in (Fig. 2). 17. Check for correct fluid level in transaxle assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation - Front Axle Half Shaft > Page 5599 Axle Shaft: Service and Repair Removal and Installation - Rear Axle Shaft REMOVAL 1. Lift vehicle on hoist so that the wheels hang freely. 2. Remove rear wheel. 3. Remove cotter pin, nut lock, and wave washer (Fig. 1). 4. Remove hub nut and washer. CAUTION: The half shaft outer CV joint, when installed, acts as a bolt and secures the hub/bearing assembly. If the vehicle is to be supported or moved on its wheels, install and torque a bolt through the hub. This will ensure that the hub/bearing assembly cannot loosen. 5. Remove inner half shaft retaining bolts (Fig. 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation - Front Axle Half Shaft > Page 5600 6. The half shaft is spring loaded. Compress inner half shaft joint slightly and pull downward to clear rear differential output flange. Then pull half shaft assembly outward to remove (Fig. 3). INSTALLATION 1. Install the outer CV joint stub shaft through the hub bearing (Fig. 4). 2. The half shaft is spring loaded. Compress inner half shaft joint slightly and push upward until the inner CV joint flange engages the rear differential output flange. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Removal and Installation - Front Axle Half Shaft > Page 5601 3. Install the inner half shaft retaining bolts (Fig. 5). Torque the bolts to 61 Nm (45 ft. lbs.). 4. Install the half shaft washer and hub nut. Torque the hub nut to 244 Nm (180 ft. lbs.). 5. Install the wave washer, nut lock, and a new cotter pin (Fig. 6). Be sure to wrap the cotter pin prongs tightly around the hub nut lock. 6. Install rear wheel. Torque the lug nuts to 135 Nm (100 ft. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle Constant Velocity Joint Boot: Service and Repair Front Axle CV Joint/Boot - Inner REMOVAL 1. Remove the half shaft requiring boot replacement from the vehicle. 2. Remove large boot clamp, which retains inner tripod joint sealing boot to tripod joint housing and discard. 3. Remove small clamp, which retains inner tripod joint sealing boot to interconnecting shaft and discard. 4. Remove the sealing boot from the tripod housing and slide it down the interconnecting shaft. CAUTION: When removing the tripod joint housing from the spider assembly, hold the bearings in place on the spider bunions to prevent the bearings from falling away. 5. Slide the tripod joint housing off the spider assembly and the interconnecting shaft (Fig. 12). 6. Remove snap-ring, which retains spider assembly, to interconnecting shaft (Fig. 13). Do not hit the outer tripod bearings in an attempt to remove spider assembly from interconnecting shaft. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5606 7. Remove the spider assembly from interconnecting shaft. If spider assembly will not come off interconnecting shaft by hand, it can be removed by tapping spider assembly with a brass drift (Fig. 14). 8. Slide sealing boot off interconnecting shaft. 9. Thoroughly clean and inspect spider assembly, tripod joint housing, and interconnecting shaft for any signs of excessive wear. If any parts show signs of excessive wear, the half shaft assembly will require replacement. Component parts of these half shaft assemblies are not serviceable. INSTALLATION 1. Slide inner CV joint seal boot retaining clamp, onto the interconnecting shaft. Then, slide the replacement inner CV joint sealing boot onto the interconnecting shaft. Inner CV joint seal boot MUST be positioned on interconnecting shaft so the raised bead on the inside of the small diameter end of the seal boot is in mating groove on interconnecting shaft (Fig. 15). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5607 2. Install spider assembly onto interconnecting shaft (Fig. 16). Spider assembly must be installed on interconnecting shaft far enough to fully install spider retaining snap-ring. If the spider assembly will not fully install on interconnecting shaft by hand, it can be installed by tapping the spider body with a brass drift (Fig. 17). Do not hit the outer tripod bearings in an attempt to install spider assembly on interconnecting shaft. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5608 3. Install the spider assembly to interconnecting shaft retaining snap-ring into groove on end of interconnecting shaft (Fig. 18). Be sure the snap-ring is fully seated into groove on interconnecting shaft. 4. Distribute 1/2 the amount of grease provided in the seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into tripod housing. Put the remaining amount into the sealing boot. 5. Align tripod housing with spider assembly and then slide tripod housing over spider assembly and interconnecting shaft (Fig. 19). 6. Install inner CV joint seal boot to interconnecting shaft clamp evenly on sealing boot. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5609 7. Place crimping tool C-4975-A over bridge of clamp (Fig. 20). 8. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 21). CAUTION: Seal boot must not be dimpled, stretched or out of shape in any way. If seal boot is NOT shaped correctly, equalize pressure in seal and shape it by hand. 9. Position sealing boot into the tripod housing retaining groove. Install seal boot retaining clamp evenly on sealing boot. 10. Position trilobal boot to interface with the tripod housing. The lobes of the boot must be properly aligned with the recesses of the tripod housing. CAUTION: The following positioning procedure determines the correct air pressure inside the inner CV joint assembly prior to clamping the sealing boot to inner CV joint housing. If this procedure is not done prior to clamping sealing boot to CV joint housing sealing boot durability can be adversely affected. CAUTION: When venting the inner CV joint assembly, use care so that the inner CV sealing boot does not get punctured, or in any other way damaged. If sealing boot is punctured, or damaged in any way while being vented, the sealing boot can not be used. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5610 11. Insert a trim stick between the CV joint housing and the sealing boot insert to vent inner CV joint assembly (Fig. 22). When inserting trim stick between tripod housing and sealing boot, ensure trim stick is held flat and firmly against the tripod housing. If this is not done damage to the sealing boot can occur. 12. With trim stick inserted between sealing boot insert and the CV joint housing, position the interconnecting shaft so it is at the center of its travel in the tripod joint housing. Remove the trim stick from between the sealing boot insert and the CV joint housing. This procedure will equalize the air pressure in the CV joint, preventing premature sealing boot failure. 13. Clamp CV joint sealing boot to CV joint, using required procedure for type of boot clamp application. CRIMP TYPE BOOT CLAMP If seal boot uses crimp type boot clamp, use the following procedure to install the retaining clamp. 1. Place crimping tool C-4975-A over bridge of clamp (Fig. 23). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5611 2. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 24). LATCHING TYPE BOOT CLAMP If seal boot uses low profile latching type boot clamp, use the following procedure to install the retaining clamp. 1. Place prongs of clamp locking tool in the holes of the clamp (Fig. 25). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5612 2. Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of clamp (Fig. 26). 14. Install the half shaft back into the vehicle. CV Joint/Boot - Outer REMOVAL 1. Remove half shaft assembly requiring boot replacement from vehicle. 2. Remove large boot clamp retaining CV joint sealing boot to CV joint housing (Fig. 27) and discard. 3. Remove small clamp that retains outer CV joint sealing boot to interconnecting shaft and discard. 4. Remove sealing boot from outer CV joint housing and slide it down interconnecting shaft. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5613 5. Wipe away grease to expose outer CV joint to interconnecting shaft retaining ring. 6. Spread ears apart on CV joint assembly to interconnecting shaft retaining ring (Fig. 28). 7. Slide outer CV joint assembly off end of interconnecting shaft. 8. Slide sealing boot off interconnecting shaft. 9. Thoroughly clean and inspect outer CV joint assembly and interconnecting joint for any signs of excessive wear. If any parts show signs of excessive wear, the half shaft assembly will require replacement. Component parts of these half shaft assemblies are not serviceable. INSTALLATION 1. Slide the new small diameter seal boot retaining clamp onto the interconnecting shaft. Then slide the replacement outer CV joint assembly sealing boot onto the interconnecting shaft. 2. Install the outer CV joint assembly onto the interconnecting shaft. Joint is installed on interconnecting shaft, by pushing interconnecting shaft into outer CV joint, until retaining ring is seated in groove on interconnecting shaft (Fig. 29). Verify that the retaining ring is fully seated into groove on interconnecting shaft. 3. Distribute 1/2 the amount of grease provided in seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into outer CV joint assembly housing. Put the remaining amount into the sealing boot. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5614 4. Install outer CV joint seal boot retaining clamp, onto interconnecting shaft. Install replacement outer CV joint sealing boot onto interconnecting shaft. Outer CV joint seal boot MUST be positioned on interconnecting shaft, so that only the thinnest (sight) groove on interconnecting shaft is visible (Fig. 30). 5. Place crimping tool C-4975-A over bridge of clamp (Fig. 31). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5615 6. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 32). CAUTION: Seal boot must not be dimpled, stretched, or out-of-shape in any way. If seal boot is NOT shaped correctly, equalize pressure in seal and shape it by hand. 7. Position outer CV joint sealing boot into its retaining groove on outer CV joint housing. 8. Install sealing boot to outer CV joint retaining clamp evenly on sealing boot. 9. Place crimping tool C- 4975-A over bridge of clamp (Fig. 33). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5616 10. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 34). 11. Install the half shaft requiring boot replacement back on the vehicle. CV Joint Bearing Shield FRONT AXLE Outer CV Joint Bearing Shield REMOVAL 1. Clamp half shaft in a vise by the interconnecting shaft. 2. Using a drift (Fig. 35) tap around the entire edge of the bearing shield until it is removed from the outer CV joint. INSTALLATION 1. Install bearing shield by hand on outer CV Joint so that it is installed squarely on the CV joint. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5617 2. Position installer, Special Tool C-4698-2, and handle, Special Tool C-4698-1, on face of bearing shield (Fig. 36). CAUTION: If bearing shield is not installed flush against the face of the outer CV joint, interference with steering knuckle will occur when driveshaft is installed. 3. Using a hammer, drive the bearing shield on the outer CV joint until it is flush against the front of the outer CV joint (Fig. 37). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5618 Constant Velocity Joint Boot: Service and Repair Rear Axle REMOVAL 1. Remove half shaft from vehicle. 2. Clamp the half shaft into a suitable vise with protective jaws clamped onto the interconnecting shaft (Fig. 7). 3. Remove the large and small diameter retaining clamps holding the CV boot to the CV joint and the interconnecting shaft (Fig. 8). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5619 4. Pull the boot back from the CV joint (Fig. 9). 5. Remove the CV housing from the interconnecting shaft and tripod assembly (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5620 6. Remove the snap-ring holding the tripod assembly onto the interconnecting shaft (Fig. 11). 7. Remove the tripod assembly from the interconnecting shaft (Fig. 12). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5621 8. Remove the CV boot from the interconnecting shaft (Fig. 13). INSTALLATION 1. Clean the interconnecting shaft and inner CV joint of any residual grease and dirt. 2. Slide the new small diameter retaining clamp onto the interconnecting shaft. 3. Install the CV boot onto the interconnecting shaft (Fig. 14). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5622 4. Install the tripod assembly onto the interconnecting shaft (Fig. 15). 5. Install the snap-ring to hold the tripod assembly onto the interconnecting shaft (Fig. 16). 6. Install the new large diameter retaining clamp onto the CV joint housing. 7. Distribute 1/2 the amount of grease provided in the seal boot service package (DO NOT USE ANY OTHER TYPE OF GREASE) into tripod housing. Put the remaining amount into the sealing boot. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5623 8. Install the CV housing onto the interconnecting shaft and tripod assembly (Fig. 17). 9. Clamp the half shaft into a suitable vise with protective jaws clamped onto the interconnecting shaft. 10. Position the inner CV joint boot on interconnecting shaft so the raised bead on the inside of the small diameter end of the seal boot is in mating groove on interconnecting shaft (Fig. 18). 11. Install inner CV joint seal boot to interconnecting shaft clamp evenly on sealing boot. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5624 12. Place crimping tool C-4975-A over bridge of clamp (Fig. 19). 13. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 20). CAUTION: The boot must not be dimpled, stretched or out of shape in any way. If boot is NOT shaped correctly, equalize pressure in boot and shape it by hand. 14. Position CV boot into the CV housing retaining groove. Install the boot large diameter retaining clamp evenly onto the boot. 15. Clamp the CV joint boot to the CV joint, using required procedure for type of boot clamp application. CRIMP TYPE BOOT CLAMP If seal boot uses crimp type boot clamp, use the following procedure to install the retaining clamp. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5625 1. Place crimping tool C-4975-A over bridge of clamp (Fig. 21). 2. Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to face (Fig. 22). LATCHING TYPE BOOT CLAMP If seal boot uses low profile latching type boot clamp, use the following procedure to install the retaining clamp. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Service and Repair > Front Axle > Page 5626 1. Place prongs of clamp locking tool in the holes of the clamp (Fig. 23). 2. Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of clamp (Fig. 24). 16. Install the half shaft into the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Hub And Bearing Mounting Bolts Front .................................................................................................................................................... ................................................. 65 Nm (45 ft. lbs.) Rear ..................................................................... ............................................................................................................................... 129 Nm (95 ft. lbs.) Hub And Bearing Axle Hub Nut .......................................................................................................................................................... 244 Nm (180 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Description and Operation > Front Wheel Bearing: Description and Operation Front HUB AND BEARING DESCRIPTION The front wheel bearing and front wheel hub of this vehicle are a hub and bearing unit type assembly (Unit III). This unit combines the front wheel mounting hub (flange) and the front wheel bearing into a sealed one-piece unit. The hub and bearing is mounted to the center of the steering knuckle. It is retained by four mounting bolts accessible from the inboard side of the steering knuckle. The hub flange has five wheel mounting studs. The wheel mounting studs used to mount the tire and wheel to the vehicle are the only replaceable components of the hub and bearing assembly. Otherwise, the hub and bearing is serviced only as a complete assembly. OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the driveshaft, along with the tire and wheel. The five wheel mounting studs mount the tire and wheel, and brake rotor to the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Description and Operation > Front > Page 5632 Wheel Bearing: Description and Operation Rear HUB AND BEARING DESCRIPTION The rear wheel bearing and rear wheel hub of this vehicle are a one-piece sealed unit, or hub and bearing unit type assembly (Unit III). The hub and bearing is mounted to the center of the rear axle using 4 mounting bolts. It has five wheel mounting studs on the hub flange. All Wheel Drive vehicles have a hub and bearing unit with a splined hole in the center of the hub for rear driveshaft stub axle acceptance. Front Wheel Drive vehicles with antilock brakes have an internally mounted wheel speed sensor and tone wheel. This hub and bearing can be identified by the rounded cap and molded in connector on the rear of the assembly. The sensor and tone wheel cannot be serviced separately from the hub and bearing. OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the tire and wheel assembly (and driveshaft on All-Wheel-Drive vehicles). The five wheel mounting studs mount the tire and wheel assembly, and disc brake rotor or brake drum to the vehicle. On All Wheel Drive vehicles, the splined mating of the driveshaft stub axle and hub allows the driveshaft to rotate with the hub and wheel. Front Wheel Drive vehicles equipped with antilock brakes have a wheel speed sensor and tone wheel mounted to the rear of the hub and bearing. The tone wheel rotates with the hub which is sensed by the wheel speed sensor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front DIAGNOSIS AND TESTING - HUB AND BEARING The condition of the front hub and bearing assembly is diagnosed using the inspection and testing procedure. The bearing contained in the Unit III front hub/bearing assembly will produce noise and vibration when worn or damaged. The noise will generally change when the bearings are loaded. A road test of the vehicle is normally required to determine the location of a worn or damaged bearing. Find a smooth level road surface and bring the vehicle up to a constant speed. When vehicle is at a constant speed, swerve the vehicle back and forth from the left and to the right. This will load and unload the bearings and change the noise level. When bearing damage is slight, the noise is sometimes noticeable at lower speeds and at other times is more noticeable at speeds above 105 km/h (65 mph). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 5635 Wheel Bearing: Testing and Inspection Rear DIAGNOSIS AND TESTING - HUB AND BEARING The bearing contained in the hub and bearing assembly will produce noise and vibration when worn or damaged. The noise will generally change when the bearings are loaded. A road test of the vehicle is normally required to determine the location of a worn or damaged bearing. Find a smooth level road surface and bring the vehicle up to a constant speed. When vehicle is at a constant speed, swerve the vehicle back and forth from the left and to the right. This will load and unload the bearings and change the noise level. When bearing damage is slight, the noise is sometimes noticeable at lower speeds and at other times is more noticeable at speeds above 105 km/h (65 mph). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front REMOVAL NOTE: Replacement of the Unit III front hub/bearing assembly can be normally done without having to remove the steering knuckle from the vehicle. In the event that the hub/bearing is frozen in the steering knuckle and cannot be removed by hand, it will have to be pressed out of the steering knuckle. The steering knuckle will require removal from the vehicle to allow the hub/bearing assembly to be pressed out of the steering knuckle. 1. Raise vehicle. 2. Remove wheel lug nuts, and front tire and wheel assembly. 3. Remove the cotter pin, nut lock and spring washer from the stub axle. 4. With aid of a helper applying the brakes to keep the front hub from turning, remove the hub nut. 5. Remove disc brake caliper and adapter as an assembly from knuckle as shown. Hang assembly out of the way using a bungee cord or wire. Do not allow caliper hang by brake hose. 6. Remove brake rotor from hub and bearing. 7. Push in on end of driveshaft stub shaft, pushing its splines out of the hub splines. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5638 8. Remove the four hub and bearing mounting bolts from the rear of steering knuckle. Use care not to come in contact with and damage the ABS tone wheel on the driveshaft stub shaft upon bolt removal. 9. Remove the hub and bearing assembly from the steering knuckle. INSTALLATION CAUTION: Hub and bearing assembly mounting surfaces on the steering knuckle and stub axle must be smooth and completely free of foreign material or nicks prior to installing hub and bearing assembly. CAUTION: When installing hub and bearing into steering knuckle, be careful not to damage the bearing seal on the outer C/V joint. 1. Install hub and bearing onto stub axle and into steering knuckle until squarely seated on the face of the steering knuckle. 2. Install the 4 hub and bearing mounting bolts from the rear of the knuckle. Equally tighten all 4 mounting bolts in a cries-cross pattern until hub/bearing assembly is squarely seated against front of steering knuckle. Tighten mounting bolts to a torque of 65 Nm (45 ft. lbs.) 3. Install the brake rotor on the hub and bearing. 4. Install brake caliper and adapter assembly back over brake rotor and align with mounting holes on steering knuckle. Install the mounting bolts and tighten to 169 Nm (125 ft. lbs.) torque. 5. Install the hub nut on the end of the stub axle. With aid of a helper applying the brakes to keep the front hub from turning, tighten the hub nut to Install the mounting bolts and tighten to 244 Nm (180 ft. lbs.) torque. 6. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 7. Lower vehicle to the ground. 8. Check the front wheel alignment toe setting and reset if not within specifications. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5639 Wheel Bearing: Service and Repair Rear REMOVAL - FWD 1. Raise vehicle. 2. Remove wheel and tire. 3. Remove brake drum or disc brake caliper and rotor from hub and bearing. 4. If equipped with antilock brakes, perform the following: a. Remove secondary (yellow) retaining clip at rear of wheel speed sensor head. b. Push up on metal retaining clip until it bottoms. This will release wheel speed sensor head from hub and bearing. c. While holding metal clip up, pull back on wheel speed sensor head removing it from hub and bearing. 5. Remove the 4 bolts attaching the hub and bearing to the rear axle. CAUTION: Corrosion may occur between the hub and bearing, and the axle. If this occurs the hub and bearing will be difficult to remove from the axle. If the hub and bearing will not come out of the axle by pulling on it by hand, do not pound on the hub and bearing to remove it from the axle. Damage will occur. Use the following procedure. 6. If the hub and bearing cannot be removed from the axle by hand, use Remover, Special Tool 8458 and the following procedure to press the hub and bearing out of the axle. a. Remove the two outboard spring plate bolts. b. Thread Threaded Guide Pins into hub and bearing mounting bolt holes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5640 c. Using the spring plate bolts, install the Screw Mount, Special Tool 8458-2, as shown. Mount the Screw Mount to the spring plate with the tool number facing the hub and bearing and the beveled edge on the bottom facing the spring, otherwise the Forcing Screw will rub the spring plate when installed. d. Place Push Plate, Special Tool 8458-1, on ends of Threaded Guide Pins e. Place a dab of grease in dimple of Push Plate. f. Install Forcing Screw, Special Tool 8458-3, through Screw Mount from rear. g. Tighten the Forcing Screw up against dimple in Push Plate and press hub and bearing out of axle by continuing to tighten screw. h. Remove the tool. i. Reinstall the two outboard spring plate bolts. Tighten the bolts to 102 Nm (75 ft. lbs.) torque. 7. Remove the hub/bearing from the rear axle and brake support plate. INSTALLATION - FWD 1. Install the 4 hub and bearing to axle mounting bolts into the holes in the flange of the rear axle. 2. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. 3. Align the rear hub and bearing with the 4 mounting bolts and start mounting bolts into hub and bearing. Tighten the 4 bolts in a crisscross pattern until the hub and bearing and brake support plate is fully and squarely seated onto flange of rear axle. Tighten the 4 mounting bolts to a torque of 129 Nm (95 ft. lbs.) NOTE: If equipped with antilock brakes, make sure wheel speed sensor stays clean and dry as it is installed into the hub and bearing cap. 4. If the vehicle is equipped with antilock brakes, perform the following: a. If metal sensor retaining clip is not in the neutral installed position on hub and bearing cap, install from the bottom, if necessary, and push clip upward until it snaps into position. b. Install wheel speed sensor head into rear of hub and bearing aligning index tab with the notch in the top of the mounting hole. Push the sensor in until it snaps into place on the metal retaining clip. c. Install secondary (yellow) retaining clip over wheel speed sensor head and engage the tabs on each side. 5. Install brake drum or disc brake rotor and brake caliper. 6. Install wheel and tire. Tighten the wheel nuts in the proper sequence to a torque of 135 Nm (100 ft. lbs.). 7. Adjust the rear brakes as necessary. 8. Lower vehicle. 9. Road test vehicle to ensure proper operation of brakes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub And Bearing Axle Hub Nut Front .................................................................................................................................................... ............................................. 244 Nm (180 ft. lbs.) Rear ..................................................................... ............................................................................................................................. 244 Nm (180 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Driveplate-to-Crankshaft Bolt .............................................................................................................. ................................................... 95 Nm (70 ft. lbs.) Torque Converter-to-Transfer Driveplate Bolt ....................................................................................................................................... 75 Nm (55 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5654 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5659 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations Control Module: Locations Control Module Locations NGC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 5665 Control Module: Description and Operation Fig.14 Transmission Control Module (TCM) Location The Transmission Control Module (TCM) is located behind the left fender and is fastened with three screws to three clips in the left frame rail forward of the suspension (Fig. 14). The TCM is the controlling unit for all electronic operations of the transaxle. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transaxle. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the J1850 communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor (CKP) - Transmission Range Sensor (TRS) - Pressure Switches (L/R, 2/4, OD) - Transmission Temperature Sensor (Integral to TRS) - Input Shaft Speed Sensor - Output Shaft Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Speed Control ON/OFF Switch - Engine Coolant Temperature - Ambient/Battery Temperature - Brake Switch Status - DRB Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids (LR/CC, 2/4, OD and UD) - Vehicle Speed (to PCM) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 5666 - Torque Reduction Request (to PCM) An example of a TCM indirect output is: - Transmission Temperature (to PCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indices (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB scan tool) Clutch Volume Index (CVI) An important function of the TCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.15 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transaxle gear ratio. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 15). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 5667 Clutch Volumes Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 5668 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 5669 Control Module: Service and Repair ELECTRONIC PINION FACTOR (IF APPLICABLE) NOTE: After replacing the EATX/PCM, you must reprogram pinion factor. In some vehicle applications, the pinion factor is a fixed value and cannot be changed or updated. The transmission output speed signal supplies distance pulses to the control module, which are used to calculate speed and mileage. A pinion factor is stored in the control module in order to provide the appropriate distance pulses for other vehicle systems. The pinion factor is programmed into the control module at the assembly plant. The pinion factor must be set when replacing the control module. If the pinion factor is not set or incorrectly set, any speed related functions will not operate correctly i.e. speedometer, speed control, rolling door locks, other control modules will be affected that depend on speed information. Using the following steps, the pinion factor can be checked and/or reset using the DRBIII: 1. Select Transmission system, then Miscellaneous functions, then Pinion Factor. The DRBIII will display the current tire size. 2. If the tire size is incorrect, press the Enter key and then select the correct size. 3. Press the Page Back key to exit the reset procedure. Notes About Electronic Pinion Factor Features The nature of the electronic pinion factor requires that certain features must be taken into consideration. ^ If no pinion factor is stored in an installed control module, the vehicle speedometer will not operate, engine speed will be limited to 2300 RPM, and catalyst damage may occur. ^ Selecting a wrong tire size will cause the speedometer to be inaccurate and will also cause any speed related features to operate improperly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5673 Transmission Control System Relay: Diagrams Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5674 Transmission Control Relay (EATX) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Transmission Control System Relay: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION CONTROL RELAY - DESCRIPTION The transmission control relay (Fig. 336) is located in the Intelligent Power Module (IPM), which is located on the left side of the engine compartment between the battery and left fender. OPERATION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5677 Transmission Control System Relay: Description and Operation 40TE Automatic Transaxle TRANSMISSION CONTROL RELAY DESCRIPTION The transmission control relay (Fig. 302) is located in the Intelligent Power Module (IPM), which is located on the left side of the engine compartment between the battery and left fender. OPERATION The Transmission Control Relay is supplied fused B+ voltage, energized by the PCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the PCM energizes the relay. Prior to this, the PCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the PCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Testing and Inspection > Pressure Switch States Pressure Switch States Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Testing and Inspection > Pressure Switch States > Page 5685 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR Sensor, Transmission Range Sensor ...................................................................................................................................................... 5 Nm (45 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 5691 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5692 Transmission Range Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 337). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 338). OPERATION The Transmission Range Sensor (TRS) (Fig. 337) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5695 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 338) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5696 Transmission Position Switch/Sensor: Description and Operation 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 303). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM/TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 304). OPERATION The Transmission Range Sensor (TRS) (Fig. 303) communicates Shift Lever Position (SLP) to the PCM/TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the PCM/TCM receives from four sense circuits. The PCM/TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the PCM/TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5697 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 304) that the PCM/TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the PCM/TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the PCM/TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 5698 Transmission Position Switch/Sensor: Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle Transmission Position Switch/Sensor: Service and Repair 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 305). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 305) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5701 Transmission Position Switch/Sensor: Service and Repair 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 339). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 339) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5702 Transmission Position Switch/Sensor: Service and Repair 41TE REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 343). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 343) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications 41TE - Automatic Transmission Sensor, Input Speed ............................................................................................................................ .................................................... 27 Nm (20 ft. lbs.) Sensor, Output Speed ...................................... ........................................................................................................................................ 27 Nm (20 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 5708 Transmission Speed Sensor: Connector Locations Transmission Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 5709 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5710 Transmission Speed Sensor: Diagrams Input Speed Sensor Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle Transmission Speed Sensor: Description and Operation 40TE Automatic Transaxle Speed Sensor Input INPUT SPEED SENSOR DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case. The Input Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5713 The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as input shaft rpm. The PCM/TCM compares the input speed signal with output speed signal to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The PCM/TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Speed Sensor Output OUTPUT SPEED SENSOR DESCRIPTION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5714 The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case. The Output Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as output shaft rpm. The PCM/TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation Vehicle Speed Signal The vehicle speed signal is taken from the Output Speed Sensor. The PCM converts this signal into a pulse per mile and sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5715 Transmission Speed Sensor: Description and Operation 41TE Automatic Transmission Input Speed Sensor INPUT SPEED SENSOR DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case. The Input Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5716 The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as input shaft rpm. The PCM/TCM compares the input speed signal with output speed signal to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The PCM/TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Output Speed Sensor OUTPUT SPEED SENSOR DESCRIPTION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5717 The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case. The Output Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as output shaft rpm. The PCM/TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation Vehicle Speed Signal The vehicle speed signal is taken from the Output Speed Sensor. The PCM converts this signal into a pulse per mile and sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle Transmission Speed Sensor: Service and Repair 40TE Automatic Transaxle Input Speed Sensor SPEED SENSOR INPUT REMOVAL 1. Disconnect battery negative cable. 2. Disconnect input speed sensor connector (Fig. 284). 3. Unscrew and remove input speed sensor (Fig. 285). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5720 4. Inspect speed sensor o-ring (Fig. 286) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 286). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.) (Fig. 285). 3. Connect speed sensor connector (Fig. 284). 4. Connect battery negative cable. Output Speed Sensor SPEED SENSOR OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector (Fig. 290). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5721 4. Unscrew and remove output speed sensor (Fig. 291). 5. Inspect speed sensor o-ring (Fig. 292) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 292). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector (Fig. 290). 4. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5722 Transmission Speed Sensor: Service and Repair 41TE Automatic Transmission Input Speed Sensor SPEED SENSOR INPUT REMOVAL 1. Disconnect battery negative cable. 2. Disconnect input speed sensor connector (Fig. 284). 3. Unscrew and remove input speed sensor (Fig. 285). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5723 4. Inspect speed sensor o-ring (Fig. 286) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 286). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.) (Fig. 285). 3. Connect speed sensor connector (Fig. 284). 4. Connect battery negative cable. Output Speed Sensor SPEED SENSOR OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector (Fig. 290). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5724 4. Unscrew and remove output speed sensor (Fig. 291). 5. Inspect speed sensor o-ring (Fig. 292) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 292). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector (Fig. 290). 4. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 5728 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5735 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5740 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation Pressure Regulating Solenoid: Description and Operation SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION The Solenoid/Pressure Switch Assembly (Fig. 276) is external to the transaxle and mounted to the transaxle case. The assembly consists of four solenoids that control hydraulic pressure to the LR/CC, 2/4, OD, and UD friction elements. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the PCM/TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The PCM/TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which by design allow fluid to pass through in their relaxed or "off" state. This allows transaxle limp-in (P, R, N, 2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the PCM/TCM during this test. It no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The PCM/TCM relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the PCM/TCM detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11-23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the PCM/TCM for the correct states (open or closed) in each gear as shown in the following chart: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 5747 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the PCM/TCM senses any switch open or closed at the wrong time in a given gear. The PCM/TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the PCM/TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 5748 Pressure Regulating Solenoid: Service and Repair SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect solenoid/pressure switch assembly connector (Fig. 277). 4. Disconnect input speed sensor connector (Fig. 277). 5. Remove input speed sensor (Fig. 278). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Description and Operation > Page 5749 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 279). 7. Remove solenoid/pressure switch assembly and gasket (Fig. 280). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 280). 2. Install and torque three (3) bolts (Fig. 279) to 13 Nm (110 inch lbs.). 3. Install input speed sensor (Fig. 278) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector (Fig. 277). 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 inch lbs.) (Fig. 277). 6. Install air cleaner assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5753 Steering Column Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5754 Brake Transmission shift Interlock Solenoid Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5755 Shift Interlock Solenoid: Service and Repair SHIFT INTERLOCK SOLENOID REMOVAL 1. Disconnect battery negative cable. 2. Remove instrument panel lower shroud (Fig. 268). 3. Remove knee bolster (Fig. 269). 4. Remove steering column lower shroud. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5756 5. Disconnect Brake/Transmission Shift Interlock (BTSI) solenoid connector (Fig. 270). 6. Remove two (2) solenoid-to-column screws (Fig. 271). 7. Remove solenoid. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5757 1. Place interlock solenoid into position ensuring hook on end of solenoid plunger engages gearshift lever pawl pin. Install and tighten screws (Fig. 272). 2. Verify gearshift lever is in PARK (P) and connect solenoid connector (Fig. 273). 3. Install steering column lower shroud. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5758 4. Install knee bolster (Fig. 274). 5. Install instrument panel lower silencer (Fig. 275). 6. Connect battery negative cable. 7. Verify proper shift interlock system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid: Specifications 41TE - Automatic Transaxle SOLENOID/PRESSURE SWITCH ASSY Bolt, Solenoid/Pressure Switch Assy. Connector .............................................................................................................................. 12 Nm (110 inch lbs.) Screw, Solenoid/Pressure Switch Assy. Connector ............................................................................................................................... 4 Nm (35 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5762 Shift Solenoid: Locations Transmission Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5763 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5764 Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5765 Transmission Solenodi/pressure Switch Assembly Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5766 Shift Solenoid: Description and Operation 41TE - Automatic Transaxle SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION The Solenoid/Pressure Switch Assembly (Fig. 313) is external to the transaxle and mounted to the transaxle case. The assembly consists of four solenoids that control hydraulic pressure to the LR/CC, 2/4, OD, and UD friction elements. The reverse clutch is controlled by line pressure from the manual valve in the valve body. The solenoids are contained within the Solenoid/Pressure Switch Assembly, and can only be serviced by replacing the assembly. The solenoid assembly also contains pressure switches that monitor and send hydraulic circuit information to the TCM. Likewise, the pressure switches can only be service by replacing the assembly. OPERATION SOLENOIDS The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individually by grounding the return wire of the solenoid needed. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operating state. The result is an apply or release of a frictional element. The 2/4 and UD solenoids are normally applied, which by design allow fluid to pass through in their relaxed or "off" state. This allows transaxle limp-in (P, R, N, 2) in the event of an electrical failure. The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. It no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pressure switch error occurs. PRESSURE SWITCHES The TCM relies on three pressure switches to monitor fluid pressure in the L/R, 2/4, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch circuit hydraulic failures occur. The range for the pressure switch closing and opening points is 11 - 23 psi. Typically the switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following chart: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5767 PRESSURE SWITCH STATES A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear. The TCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are operational, by looking for a closed state when the corresponding element is applied. Immediately after a shift into 1st, 2nd, or 3rd gear with the engine speed above 1000 rpm, the TCM momentarily turns on element pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it doesn't close, it is tested again. If the switch fails to close the second time, the appropriate Diagnostic Trouble Code (DTC) will set. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5768 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5769 Shift Solenoid: Service and Repair 41TE - Automatic Transaxle SOLENOID/PRESSURE SWITCH ASSY REMOVAL NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Disconnect battery negative cable. 2. Remove air cleaner assembly. 3. Disconnect solenoid/pressure switch assembly connector. 4. Disconnect input speed sensor connector. 5. Remove input speed sensor (Fig. 314). 6. Remove three (3) solenoid/pressure switch assembly-to-transaxle case bolts (Fig. 315). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5770 7. Remove solenoid/pressure switch assembly and gasket (Fig. 316). Use care to prevent gasket material and foreign objects from become lodged in the transaxle case ports. INSTALLATION NOTE: If solenoid/pressure switch assembly is being replaced, it is necessary to perform the TCM Quick Learn Procedure. 1. Install solenoid/pressure switch assembly and new gasket to transaxle (Fig. 316). 2. Install and torque three (3) bolts (Fig. 315) to 13 Nm (110 inch lbs.). 3. Install input speed sensor (Fig. 314) and torque to 27 Nm (20 ft. lbs.). 4. Connect input speed sensor connector. 5. Install solenoid/pressure switch 8-way connector and torque to 4 Nm (35 inch lbs.). 6. Install air cleaner assembly. 7. Connect battery negative cable. 8. If solenoid/pressure switch assembly was replaced, perform TCM Quick Learn procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations Control Module: Locations Control Module Locations NGC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 5776 Control Module: Description and Operation Fig.14 Transmission Control Module (TCM) Location The Transmission Control Module (TCM) is located behind the left fender and is fastened with three screws to three clips in the left frame rail forward of the suspension (Fig. 14). The TCM is the controlling unit for all electronic operations of the transaxle. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transaxle. Direct inputs are hardwired to, and used specifically by the TCM. Indirect inputs originate from other components/modules, and are shared with the TCM via the J1850 communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) - Throttle Position Sensor - Crankshaft Position Sensor (CKP) - Transmission Range Sensor (TRS) - Pressure Switches (L/R, 2/4, OD) - Transmission Temperature Sensor (Integral to TRS) - Input Shaft Speed Sensor - Output Shaft Speed Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Speed Control ON/OFF Switch - Engine Coolant Temperature - Ambient/Battery Temperature - Brake Switch Status - DRB Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids (LR/CC, 2/4, OD and UD) - Vehicle Speed (to PCM) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 5777 - Torque Reduction Request (to PCM) An example of a TCM indirect output is: - Transmission Temperature (to PCM) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indices (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with DRB scan tool) Clutch Volume Index (CVI) An important function of the TCM is to monitor Clutch Volume Index (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. Fig.15 Example Of CVI Calculation By comparing the two inputs, the TCM can determine transaxle gear ratio. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur (Fig. 15). Gear ratios can be determined by using the DRB Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 5778 Clutch Volumes Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following chart identifies the appropriate clutch volumes and when they are monitored/updated: Shift Schedules As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: Shift lever position - Throttle position - Engine load - Fluid temperature - Software level Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 5779 As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations > Page 5780 Control Module: Service and Repair ELECTRONIC PINION FACTOR (IF APPLICABLE) NOTE: After replacing the EATX/PCM, you must reprogram pinion factor. In some vehicle applications, the pinion factor is a fixed value and cannot be changed or updated. The transmission output speed signal supplies distance pulses to the control module, which are used to calculate speed and mileage. A pinion factor is stored in the control module in order to provide the appropriate distance pulses for other vehicle systems. The pinion factor is programmed into the control module at the assembly plant. The pinion factor must be set when replacing the control module. If the pinion factor is not set or incorrectly set, any speed related functions will not operate correctly i.e. speedometer, speed control, rolling door locks, other control modules will be affected that depend on speed information. Using the following steps, the pinion factor can be checked and/or reset using the DRBIII: 1. Select Transmission system, then Miscellaneous functions, then Pinion Factor. The DRBIII will display the current tire size. 2. If the tire size is incorrect, press the Enter key and then select the correct size. 3. Press the Page Back key to exit the reset procedure. Notes About Electronic Pinion Factor Features The nature of the electronic pinion factor requires that certain features must be taken into consideration. ^ If no pinion factor is stored in an installed control module, the vehicle speedometer will not operate, engine speed will be limited to 2300 RPM, and catalyst damage may occur. ^ Selecting a wrong tire size will cause the speedometer to be inaccurate and will also cause any speed related features to operate improperly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5784 Transmission Control System Relay: Diagrams Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5785 Transmission Control Relay (EATX) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Transmission Control System Relay: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION CONTROL RELAY - DESCRIPTION The transmission control relay (Fig. 336) is located in the Intelligent Power Module (IPM), which is located on the left side of the engine compartment between the battery and left fender. OPERATION The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the TCM energizes the relay. Prior to this, the TCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5788 Transmission Control System Relay: Description and Operation 40TE Automatic Transaxle TRANSMISSION CONTROL RELAY DESCRIPTION The transmission control relay (Fig. 302) is located in the Intelligent Power Module (IPM), which is located on the left side of the engine compartment between the battery and left fender. OPERATION The Transmission Control Relay is supplied fused B+ voltage, energized by the PCM, and is used to supply power to the solenoid pack when the transmission is in normal operating mode. When the relay is "off", no power is supplied to the solenoid pack and the transmission is in "limp-in" mode. After a controller reset (ignition key turned to the "run" position or after cranking engine), the PCM energizes the relay. Prior to this, the PCM verifies that the contacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the PCM monitors the terminals to verify that the voltage is greater than 3 volts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Testing and Inspection > Pressure Switch States Pressure Switch States Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Testing and Inspection > Pressure Switch States > Page 5796 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications Transmission Position Switch/Sensor: Specifications 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR Sensor, Transmission Range Sensor ...................................................................................................................................................... 5 Nm (45 inch lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations Transmission Position Switch/Sensor: Component Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Component Locations > Page 5802 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5803 Transmission Range Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission Transmission Position Switch/Sensor: Description and Operation 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 337). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 338). OPERATION The Transmission Range Sensor (TRS) (Fig. 337) communicates Shift Lever Position (SLP) to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes, which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5806 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 338) that the TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature, which is calculated from a combination of inputs: - Battery (ambient) temperature - Engine coolant temperature - In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5807 Transmission Position Switch/Sensor: Description and Operation 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor (TRS) is mounted to the top of the valve body inside the transaxle and can only be serviced by removing the valve body. The electrical connector extends through the transaxle case (Fig. 303). The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM/TCM. The TRS also has an integrated temperature sensor (thermistor) that communicates transaxle temperature to the TCM and PCM (Fig. 304). OPERATION The Transmission Range Sensor (TRS) (Fig. 303) communicates Shift Lever Position (SLP) to the PCM/TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the PCM/TCM receives from four sense circuits. The PCM/TCM interprets this information and determines the appropriate transaxle gear position and shift schedule. Since there are four switches, there are 16 possible combinations of open and closed switches (codes). Seven of these codes are related to gear position and three are recognized as "between gear" codes. This results in six codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the PCM/TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > 41TE Automatic Transmission > Page 5808 TRS SWITCH STATES TRANSMISSION TEMPERATURE SENSOR The TRS has an integrated thermistor (Fig. 304) that the PCM/TCM uses to monitor the transmission's sump temperature. Since fluid temperature can affect transmission shift quality and convertor lock up, the PCM/TCM requires this information to determine which shift schedule to operate in. The PCM also monitors this temperature data so it can energize the vehicle cooling fan(s) when a transmission "overheat" condition exists. If the thermistor circuit fails, the PCM/TCM will revert to calculated oil temperature usage. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: ^ Battery (ambient) temperature ^ Engine coolant temperature ^ In-gear run time since start-up Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Page 5809 Transmission Position Switch/Sensor: Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle Transmission Position Switch/Sensor: Service and Repair 40TE Automatic Transaxle TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 305). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 305) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5812 Transmission Position Switch/Sensor: Service and Repair 41TE Automatic Transmission 41TE - Automatic Transmission TRANSMISSION RANGE SENSOR REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 339). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 339) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. 18 bolts. 12N.m (105 in.lb.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5813 Transmission Position Switch/Sensor: Service and Repair 41TE REMOVAL 1. Remove valve body assembly from transaxle. 2. Remove transmission range sensor retaining screw and remove sensor from valve body (Fig. 343). 3. Remove TRS from manual shaft. INSTALLATION 1. Install Transmission Range Sensor (TRS) to the valve body and torque retaining screw (Fig. 343) to 5 Nm (45 inch lbs.). 2. Install valve body to transaxle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications Transmission Speed Sensor: Specifications 41TE - Automatic Transmission Sensor, Input Speed ............................................................................................................................ .................................................... 27 Nm (20 ft. lbs.) Sensor, Output Speed ...................................... ........................................................................................................................................ 27 Nm (20 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations Transmission Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 5819 Transmission Speed Sensor: Connector Locations Transmission Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Component Locations > Page 5820 Automatic Transmission Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5821 Transmission Speed Sensor: Diagrams Input Speed Sensor Output Speed Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle Transmission Speed Sensor: Description and Operation 40TE Automatic Transaxle Speed Sensor Input INPUT SPEED SENSOR DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case. The Input Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5824 The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as input shaft rpm. The PCM/TCM compares the input speed signal with output speed signal to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The PCM/TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Speed Sensor Output OUTPUT SPEED SENSOR DESCRIPTION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5825 The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case. The Output Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as output shaft rpm. The PCM/TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation Vehicle Speed Signal The vehicle speed signal is taken from the Output Speed Sensor. The PCM converts this signal into a pulse per mile and sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5826 Transmission Speed Sensor: Description and Operation 41TE Automatic Transmission Input Speed Sensor INPUT SPEED SENSOR DESCRIPTION The Input Speed Sensor is a two-wire magnetic pickup device that generates AC signals as rotation occurs. It is threaded into the transaxle case. The Input Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5827 The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as input shaft rpm. The PCM/TCM compares the input speed signal with output speed signal to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation The PCM/TCM also compares the input speed signal and the engine speed signal to determine the following: - Torque converter clutch slippage - Torque converter element speed ratio Output Speed Sensor OUTPUT SPEED SENSOR DESCRIPTION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Description and Operation > 40TE Automatic Transaxle > Page 5828 The Output Speed Sensor is a two-wire magnetic pickup device that generates an AC signal as rotation occurs. It is threaded into the transaxle case. The Output Speed Sensor is sealed with an O-ring, and is considered a primary input to the Powertrain/Transmission Control Module. OPERATION The Output Speed Sensor provides information on how fast the output shaft is rotating. As the rear planetary carrier park pawl lugs pass by the sensor coil, an AC voltage is generated and sent to the PCM/TCM. The PCM/TCM interprets this information as output shaft rpm. The PCM/TCM compares the input and output speed signals to determine the following: - Transmission gear ratio - Speed ratio error detection - CVI calculation Vehicle Speed Signal The vehicle speed signal is taken from the Output Speed Sensor. The PCM converts this signal into a pulse per mile and sends the vehicle speed message across the communication bus to the BCM. The BCM sends this signal to the Instrument Cluster to display vehicle speed to the driver. The vehicle speed signal pulse is roughly 8000 pulses per mile. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle Transmission Speed Sensor: Service and Repair 40TE Automatic Transaxle Input Speed Sensor SPEED SENSOR INPUT REMOVAL 1. Disconnect battery negative cable. 2. Disconnect input speed sensor connector (Fig. 284). 3. Unscrew and remove input speed sensor (Fig. 285). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5831 4. Inspect speed sensor o-ring (Fig. 286) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 286). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.) (Fig. 285). 3. Connect speed sensor connector (Fig. 284). 4. Connect battery negative cable. Output Speed Sensor SPEED SENSOR OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector (Fig. 290). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5832 4. Unscrew and remove output speed sensor (Fig. 291). 5. Inspect speed sensor o-ring (Fig. 292) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 292). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector (Fig. 290). 4. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5833 Transmission Speed Sensor: Service and Repair 41TE Automatic Transmission Input Speed Sensor SPEED SENSOR INPUT REMOVAL 1. Disconnect battery negative cable. 2. Disconnect input speed sensor connector (Fig. 284). 3. Unscrew and remove input speed sensor (Fig. 285). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5834 4. Inspect speed sensor o-ring (Fig. 286) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 286). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.) (Fig. 285). 3. Connect speed sensor connector (Fig. 284). 4. Connect battery negative cable. Output Speed Sensor SPEED SENSOR OUTPUT REMOVAL 1. Disconnect battery negative cable. 2. Raise vehicle on hoist. 3. Disconnect output speed sensor connector (Fig. 290). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > 40TE Automatic Transaxle > Page 5835 4. Unscrew and remove output speed sensor (Fig. 291). 5. Inspect speed sensor o-ring (Fig. 292) and replace if necessary. INSTALLATION 1. Verify o-ring is installed into position (Fig. 292). 2. Install and tighten input speed sensor to 27 Nm (20 ft. lbs.). 3. Connect speed sensor connector (Fig. 290). 4. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations > Page 5839 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5848 3.3-3.8 Liter Engine Front Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5849 Electronic Brake Control Module: Diagrams Anti-Lock Brake Module(MK25e) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5850 Controller ANTILOCK Brake (MK20E) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > System Overview Electronic Brake Control Module: Description and Operation System Overview CONTROLLER ANTILOCK BRAKE/ANTI-LOCK BRAKE MODULE The CAB/ABM is a microprocessor-based device that monitors wheel speeds and controls the antilock functions. The CAB/ABM contains two microprocessors that receive identical sensor signals and then independently process the information. The results are then compared to make sure that they agree. Otherwise, the CAB/ABM will turn off the antilock and turn on the ABS amber warning indicator. The primary functions of the CAB/ABM are to: ^ detect wheel locking tendencies ^ control fluid pressure modulation to the brakes during antilock stop ^ monitor the system for proper operation ^ manage traction control functions ^ provide communication to the DRBIII(R) while in diagnostic mode ^ store diagnostic information in non-volatile memory The CAB/ABM continuously monitors the speed of each wheel. When a wheel locking tendency is detected, the CAB/ABM will command the appropriate valve to modulate brake fluid pressure in its hydraulic unit. Brake pedal position is maintained during an antilock stop by being a closed system. The CAB/ABM continues to control pressure in individual hydraulic circuits until a wheel locking tendency is no longer present. The CAB/ABM turns on the pump motor during an antilock stop. The antilock brake system is constantly monitored by the CAB/ABM for proper operation. If the CAB/ABM detects a system malfunction, it can disable the antilock system and turn on the ABS warning indicator. If the antilock function is disabled, the system will revert to standard base brake system operation. The CAB/ABM inputs include the following: ^ diagnostic communication ^ four wheel speed sensors ^ three power feeds: valve, pump, and microprocessor ^ brake lamp switch ^ traction control switch The CAB/ABM outputs include the following: ^ ABS warning indicator actuation ^ 12 volts supply to wheel speed sensors ^ valve actuation ^ diagnostic communication ^ PCI bus communication ^ traction control lamp illumination Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > System Overview > Page 5853 Electronic Brake Control Module: Description and Operation Antilock Brake Module (MK25E) The Antilock Brake Module (ABM) is a microprocessor-based device which monitors the antilock brake system (ABS) during normal braking and controls it when the vehicle is in an ABS stop or when in a traction control situation. The ABM utilizes a 47-way electrical connector on the vehicle wiring harness. The power source for the ABM is through the ignition switch in the RUN or ON position. Mk25e ICU The ABM is mounted to the HCU as part of the Integrated Control Unit (ICU). The ICU is located in the engine compartment below the master cylinder on the front suspension cradle/crossmember. The primary functions of the Antilock Brake Module (ABM) are to: - Monitor the antilock brake system for proper operation. - Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - Control fluid modulation to the wheel brakes while the system is in an ABS mode. - Store diagnostic information. - Provide communication to the scan tool while in diagnostic mode. - Illuminate the amber ABS warning indicator lamp. - (With traction control only) Illuminate the TRAC ON lamp in the message center on the instrument panel when a traction control event occurs. - (with traction control only) Illuminate the TRAC OFF lamp when the amber ABS warning indicator lamp illuminates. The ABM constantly monitors the antilock brake system for proper operation. If the ABM detects a fault, it will turn on the amber ABS warning indicator lamp and disable the antilock braking system. The normal base braking system will remain operational. NOTE: If the vehicle is equipped with traction control, the TRAC OFF lamp will illuminate anytime the amber ABS warning indicator lamp illuminates. The ABM continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the ABM commands the ABM command coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The ABM continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The ABM contains a self-diagnostic program that monitors the antilock brake system for system faults. When a fault is detected, the amber ABS warning indicator lamp is turned on and the fault diagnostic trouble code (DTC) is then stored in a diagnostic program memory. A latched fault will disable certain system functionality for the current ignition cycle. An unlatched fault will disable certain system functionality until the fault condition disappears. These DTC's will remain in the ABM memory even after the ignition has been turned off. The DTC's can be read and cleared from the ABM memory by a technician using a scan tool. If not cleared with a scan tool, the fault occurrence and DTC will be automatically cleared from the ABM memory after the identical fault has not been seen during the next 3,500 miles. Drive-off may be required for the amber ABS warning indicator lamp to go out on the next ignition cycle. ABM INPUTS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > System Overview > Page 5854 - Wheel speed sensors (four) - Brake lamp switch - Ignition switch - System and pump voltage - Ground - Traction control switch (if equipped) - Diagnostic communication (PCI) ABM OUTPUTS - Amber ABS warning indicator lamp actuation (via BUS) - Red BRAKE warning indicator lamp actuation (via BUS) - Instrument cluster (MIC) communication (PCI) - Traction control lamps (if equipped) - Diagnostic communication (PCI, via BUS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > System Overview > Page 5855 Electronic Brake Control Module: Description and Operation Controller Antilock Brake (MK20E) Integrated Control Unit (ICU) The controller antilock brake (CAB) is a microprocessor-based device which monitors the antilock brake system (ABS) during normal braking and controls it when the vehicle is in an ABS stop. The CAB is mounted to the HCU as part of the integrated control unit (ICU). The CAB uses a 24-way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the RUN or ON position. The CAB is on the PCI bus. The primary functions of the controller antilock brake (CAB) are to: - Monitor the antilock brake system for proper operation. - Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - Control fluid modulation to the wheel brakes while the system is in an ABS mode. - Store diagnostic information. - Provide communication to the DRBIII(R) scan tool while in diagnostic mode. - Illuminate the amber ABS warning indicator lamp. - (With traction control only) Illuminate the TRAC ON lamp in the message center on the instrument panel when a traction control event occurs. - (with traction control only) Illuminate the TRAC OFF lamp when the amber ABS warning indicator lamp illuminates. The CAB constantly monitors the antilock brake system for proper operation. If the CAB detects a fault, it will turn on the amber ABS warning indicator lamp and disable the antilock braking system. The normal base braking system will remain operational. NOTE: If the vehicle is equipped with traction control, the TRAC OFF lamp will illuminate anytime the amber ABS warning indicator lamp illuminates. The CAB continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the CAB commands the CAB command coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The CAB contains a self-diagnostic program that monitors the antilock brake system for system faults. When a fault is detected, the amber ABS warning indicator lamp is turned on and the fault diagnostic trouble code (DTC) is then stored in a diagnostic program memory. A latched fault will disable certain system functionality for the current ignition cycle. An unlatched fault will disable certain system functionality until the fault condition disappears. These DTC's will remain in the CAB memory even after the ignition has been turned off. The DTC's can be read and cleared from the CAB memory by a technician using the DRBIII(R) scan tool. If not cleared with a DRBIII(R) scan tool, the fault occurrence and DTC will be automatically cleared from the CAB memory after the identical fault has not been seen during the next 3,500 miles. Drive-off may be required for the amber ABS warning indicator lamp to go out on the next ignition cycle. CAB INPUTS - Wheel speed sensors (four) - Brake lamp switch - Ignition switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > System Overview > Page 5856 - System and pump voltage - Ground - Traction control switch (if equipped) - Diagnostic communication (PCI) CAB OUTPUTS - Amber ABS warning indicator lamp actuation (via BUS) - Red BRAKE warning indicator lamp actuation (via BUS) - Instrument cluster (MIC) communication (PCI) - Traction control lamps (if equipped) - Diagnostic communication (PCI, via BUS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Brake Module (MK25E) Electronic Brake Control Module: Service and Repair Antilock Brake Module (MK25E) REMOVAL 1. Disconnect the negative (ground) cable from the battery and isolate it. 2. Remove the battery shield and battery. 3. Disconnect the vacuum hose connector at the tank built into the battery tray. 4. Remove the screw securing the engine coolant filler neck to the battery tray. 5. Remove the battery tray. CAUTION: Before disassembling the ICU, the ICU must be thoroughly cleaned. This must be done to prevent dirt particles and debris from entering into vital areas of the ICU. 6. Thoroughly clean all surfaces of the ICU and brake tubes. Use only a solvent such as Mopar Brake Parts Cleaner or equivalent. ABM Connector Release Tabs Wiring Harness Connector At ABM 7. Disconnect the 47-way connector from the antilock brake module (ABM) by depressing the tabs on each side of the connector cover (Fig. 2), then pulling outward and upward on the lower half of the cover until it locks into position pointing straight outward. The connector can then be pulled straight outward off the ABM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Brake Module (MK25E) > Page 5859 ABM Mounting Screws - Without Traction Control 8. If not equipped with traction control, remove the three screws attaching the ABM to the HCU. ABM Mounting Screws - With Traction Control 9. If equipped with traction control, remove the four screws attaching the ABM to the HCU. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Brake Module (MK25E) > Page 5860 ABM Assembly To HCU 10. Separate the ABM from the HCU. INSTALLATION 1. Clean any debris off the mating surfaces of the HCU and ABM. CAUTION: - Do not reuse internal pump connector O-ring or solenoid valve stem seals. They must be replaced to ensure proper sealing. - When installing new O-rings or solenoid valve stem seals, do not use any type of lubricant. Solenoid Valve Seal 2. Replace solenoid valve stem seals. These seals can be easily removed and installed by hand. Do not use any type of sharp instrument or damage to the components may occur. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Brake Module (MK25E) > Page 5861 Internal Pump Connector O-Ring 3. Replace pump/motor connector O-ring if not new. 4. Align components and install the ABM on the HCU. 5. If not equipped with traction control, install the three screws attaching the ABM to the HCU. Tighten the mounting screws to 2 N.m (17 in. lbs.) torque. 6. If equipped with traction control, install the four screws attaching the ABM to the HCU. Tighten the mounting screws to 2 N.m (17 in. lbs.) torque. 7. With connector cover completely open, install 47-way wiring connector into socket of the ABM and close cover, locking connector in place. 8. Install the battery tray. 9. Install the screw securing the coolant filler neck to the battery tray. 10. Reconnect the vacuum hose connector at the tank built into the battery tray. 11. Install the battery and battery shield. 12. Connect the negative cable on the battery negative post. 13. Hook up a scan tool to initialize ABM and check for any faults. 14. Road test vehicle to ensure proper operation of brakes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Brake Module (MK25E) > Page 5862 Electronic Brake Control Module: Service and Repair Controller Antilock Brake (MK20E) REMOVAL 1. Disconnect the battery cables. 2. Remove the battery. 3. Disconnect the vacuum hose connector at the tank built into the battery tray. 4. Remove the screw securing the coolant filler neck to the battery tray. 5. Remove the battery tray. CAB Connector Lock 6. Pull up on the CAB connector lock and disconnect the 24-way electrical connector. 7. Disconnect the pump/motor connector from the CAB. CAB Mounting Screws 8. Remove the screws securing the CAB to the HCU. 9. Pull CAB straight forward off HCU. INSTALLATION 1. Slide the CAB onto the HCU. 2. Install screws securing the CAB to the HCU. Tighten the mounting screws to 2 N.m (17 in lbs). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Brake Module (MK25E) > Page 5863 3. Reconnect the 24-way wiring connector and the pump/motor wiring connector. 4. Install the battery tray. 5. Install the screw securing the coolant filler neck to the battery tray. 6. Reconnect the vacuum hose to the coolant tank built into the battery tray. 7. Install the battery. 8. Reconnect the battery cables. 9. Connect a DRBIII(R) to the vehicle. Check and clear any faults, and initialize the system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > System Description and Operation Hydraulic Control Assembly - Antilock Brakes: Description and Operation System Description and Operation MK20E DESCRIPTION - MK20e On vehicles equipped with the MK20e ABS, the hydraulic control unit (HCU) is mounted to the CAB as part of the ICU (Fig. 6). The HCU controls the flow of brake fluid to the brakes using a series of valves and accumulators. A pump/motor is mounted on the HCU to supply build pressure to the brakes during an ABS stop. OPERATION - HYDRAULIC CIRCUITS AND VALVES - MK20e NOTE: The following applies for Mark 20e ABS only. The hydraulic fluid control valves control the flow of pressurized brake fluid to the wheel brakes during the different modes of ABS braking. The following paragraphs explain how this works. For purposes of explanation only, it is assumed that only the right front wheel is experiencing antilock braking; the following diagrams show only the right front wheel in an antilock braking operation. NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 5868 The hydraulic diagram (Fig. 8) shows the vehicle in the normal braking mode of the base brake hydraulic system. The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle. The driver is applying the brake pedal which builds pressure in the brake hydraulic system to engage the brakes and stop the vehicle. ABS PRIMARY HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 5869 The hydraulic diagram (Fig. 9) shows the vehicle in the ABS braking mode. The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding. ^ The normally open and normally closed valves modulate (build/decay) the brake hydraulic pressure as required. ^ The pump/motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits. ^ The brake fluid is routed to either the master cylinder or the wheel brake depending on the position of the normally open valve. ABS SECONDARY HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 5870 The hydraulic diagram (Fig. 10) shows the vehicle in the ABS braking mode. The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding. ^ The normally open and normally closed valves modulate (build/decay) the brake hydraulic pressure as required. ^ The pump/motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits. ^ The brake fluid will then be routed to either the master cylinder or the wheel brake depending on the position of the normally open valve. ^ In the secondary circuit, 1.2 cc brake fluid is taken in by the lip seal saver to protect the lip seals on the master cylinder piston. NORMAL BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 5871 The hydraulic diagram (Fig. 11) shows a vehicle with traction control in the normal braking mode. The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle. The driver is applying the brake pedal which builds pressure in the brake hydraulic system to engage the brakes and stop the vehicle. the hydraulic shuttle valve closes with every brake pedal application so pressure is not created at the inlet to the pump/motor. ABS BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 5872 The hydraulic diagram (Fig. 12) shows the vehicle in the ABS braking mode. The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding. ^ The hydraulic shuttle valve closes upon brake application so that the pump/motor cannot siphon brake fluid from the master cylinder. ^ The normally open and normally closed valves modulate (build/decay) the brake hydraulic pressure as required. ^ The pump/motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits. ^ The brake fluid is routed to either the master cylinder or the wheel brake depending on the position of the normally open valve. ABS TRACTION CONTROL HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 5873 The hydraulic diagram (Fig. 13) shows the vehicle in the ABS braking mode. The diagram shows a drive wheel is spinning and brake pressure is required to reduce its speed. ^ The normally open ASR valve is energized to isolate the brake fluid being pumped from the master cylinder and to isolate the driven wheel. ^ The normally open ASR valve bypasses the pump output back to the master cylinder at a fixed pressure setting. ^ The normally open and normally closed valves modulate (build/decay) the brake pressure as required to the spinning wheel. MK25E DESCRIPTION - MK25E Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 5874 On Later Launch production vehicles (which are equipped with the MK25e ABS), the hydraulic control unit (HCU) is mounted to the ABM as part of the ICU (Fig. 7). The HCU controls the flow of brake fluid to the brakes using a series of valves and accumulators. A pump/motor is mounted on the HCU to supply build pressure to the brakes during an ABS stop. OPERATION - HYDRAULIC CIRCUITS AND VALVES - MK25e NOTE: The following applies for MK25e ABS only. The hydraulic fluid control valves within the HCU control the flow of pressurized brake fluid to the wheel brakes during the different modes of ABS braking and traction control. The following paragraphs explain how this works. For purposes of explanation only, the following diagrams show only one hydraulic circuit, the Right Front wheel braking circuit. NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 5875 The hydraulic diagram shows the vehicle in the normal braking mode of the base brake hydraulic system (Fig. 14). The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle. The driver is applying the brake pedal which builds pressure in the brake hydraulic system to engage the brakes and stop the vehicle. ABS HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 5876 The hydraulic diagram shows the vehicle in the ABS braking mode (Fig. 15). The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding. ^ The normally open and normally closed valves modulate (build/decay) the brake hydraulic pressure as required. ^ The pump/motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits. ^ The brake fluid is routed to either the master cylinder or the wheel brake depending on the position of the normally open valve. NORMAL BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 5877 The hydraulic diagram shows a vehicle with traction control in the normal braking mode (Fig. 16). The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle. The driver is applying the brake pedal which builds pressure in the brake hydraulic system to engage the brakes and stop the vehicle. The hydraulic shuttle valve closes with every brake pedal application so pressure is not created at the inlet to the pump/motor. ABS BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 5878 The hydraulic diagram shows the vehicle in the ABS braking mode (Fig. 17). The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding. ^ The hydraulic shuttle valve closes upon brake application so that the pump/motor cannot siphon brake fluid from the master cylinder. ^ The normally open and normally closed valves modulate (build/decay) the brake hydraulic pressure as required. ^ The pump/motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits. ^ The brake fluid is routed to either the master cylinder or the wheel brake depending on the position of the normally open valve. ABS TRACTION CONTROL HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 5879 The hydraulic diagram shows the vehicle in the traction control (TC) mode (Fig. 18). The diagram shows a drive wheel is spinning and brake pressure is required to reduce its speed. ^ The normally open TC (ASR) valve is energized to isolate the brake fluid being pumped from the master cylinder and to isolate the driven wheel. ^ The normally open TC (ASR) valve bypasses the pump output back to the master cylinder at a fixed pressure setting. ^ The normally open and normally closed valves modulate (build/decay) the brake pressure as required to the spinning wheel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 5880 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control Unit (HCU) HYDRAULIC CONTROL UNIT The hydraulic control unit (HCU) contains the valve block assembly, and pump/motor assembly The HCU is attached to the CAB/ABM. Valve Block Assembly: The valve block assembly contains valves with four inlet valves and four outlet valves. The inlet valves are spring-loaded in the open position and the outlet valves are spring loaded in the closed position. During an antilock stop, these valves are cycled to maintain the proper slip ratio for each wheel. If a wheel detects slip, the inlet valve is closed to prevent and further pressure increase. Then the outlet valve is opened to release the pressure to the accumulators until the wheel is no longer slipping. Once the wheel is no longer slipping, the outlet valve is closed and the inlet valve is opened to reapply pressure. If the wheel is decelerating within its predetermined limits (proper slip ratio), the inlet valve will close to hold the pressure constant. On vehicles which are equipped with a traction control system, there are four additional valves, two isolate the master cylinder and two shuttle. During a traction control event the brakes are applied to reduce wheel slippage. Pump Motor Assembly: The pump motor assembly provides the extra amount of fluid needed during antilock braking. The pump is supplied fluid that is released to the accumulators when the outlet valve is opened during an antilock stop. The pump is also used to drain the accumulator circuits after the antilock stop is complete. The pump is operated by an integral electric motor. This motor is controlled by the CAB/ABM. The CAB/ABM may turn on the pump motor when an antilock stop is detected. The pump continues to run during the antilock stop and is turned off after the stop is complete. Under some conditions, the pump motor will run to drain the accumulators during the next drive off. The CAB/ABM monitors the pump motor operation internally. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 5881 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Integrated Control Unit (ICU) MK20E INTEGRATED CONTROL UNIT (ICU) MK20E DESCRIPTION The hydraulic control unit (HCU) and the controller antilock brake (CAB) used with this antilock brake system are combined (integrated) into one unit, which is called the integrated control unit (ICU) (Fig. 19). Depending on whether the vehicle is Left-Hand Drive (LHD) or Right-Hand-Drive (RHD), the integrated control unit (ICU) is located in one of two locations. On LHD models, the ICU (and mounting bracket) is mounted to the front suspension cradle/crossmember below the master cylinder (Fig. 20). On RHD models, the ICU is located behind the front suspension cradle/crossmember on the left side of the vehicle. Two different ICU's (HCU and CAB) are used on this vehicle depending on whether or not the vehicle is equipped with traction control. The HCU on a vehicle equipped with traction control has a valve block that is approximately one inch longer than a HCU on a vehicle that is equipped with ABS only. The ABS-only ICU consists of the following components: the CAB, eight (build/decay) solenoid valves (four inlet valves and four outlet valves), valve block, fluid accumulators, a pump, and an electric motor. The ABS-with traction control ICU consists of the following components: the CAB, eight (build/decay) solenoid valves (four inlet valves and four outlet valves), two traction control (ASR) valves, two hydraulic shuttle valves, valve block, fluid accumulators, a pump, and an electric motor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 5882 The replaceable components of the ICU are the HCU and the CAB. No attempt should be made to service any individual components of the HCU or CAB. OPERATION For information of the ICU, refer to these individual components of the ICU: ^ CONTROLLER ANTILOCK BRAKE (CAB) ^ HYDRAULIC CONTROL UNIT (HCU) MK25E INTEGRATED CONTROL UNIT (ICU) - MK25E DESCRIPTION The Hydraulic Control Unit (HCU) and the Antilock Brake Module (ABM) used with this antilock brake system are combined (integrated) into one unit, which is called the Integrated Control Unit (ICU) (Fig. 33). The ICU is located below the master cylinder in the engine compartment. It is mounted to the front suspension cradle/crossmember. The ABS ICU consists of the following components: the ABM, eight (build/decay) solenoid valves (four inlet valves and four outlet valves) and one hydraulic pump motor. The ABS ICU with traction control consists of the following components: the ABM, eight (build/decay) solenoid valves (four inlet valves and four outlet valves), two master cylinder isolation valves, two low pressure feed valves and one hydraulic pump motor. The replaceable components of the ICU are the HCU and the ABM. No attempt should be made to service any individual components of the HCU or ABM. OPERATION For information of the ICU, refer to these individual components of the ICU: ^ ANTILOCK BRAKE MODULE (ABM) ^ HYDRAULIC CONTROL UNIT (HCU) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation Hydraulic Control Assembly - Antilock Brakes: Service and Repair ICU - Removal and Installation LHD INTEGRATED CONTROL UNIT (ICU) MK20E REMOVAL - LHD 1. Disconnect the negative (ground) cable from the battery and isolate cable. 2. Remove the battery shield. 3. Remove the battery. 4. Disconnect the vacuum hose connector at the tank built into the battery tray. 5. Remove the screw securing the engine coolant filler neck to the battery tray. 6. Remove the battery tray. 7. Using a brake pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This will prevent brake fluid from draining out of the master cylinder once the brake tubes are removed from the HCU. CAUTION: Do not apply a 12-volt power source to any terminals of the 24-way CAB connector when disconnected. 8. Disconnect the wiring harness connector from the speed control servo. 9. Remove the speed control servo mounting nuts and move the servo out of the way. 10. Disconnect the 24-way connector from the CAB. To disconnect the 24-way connector, grasp the lock on the 24-way connector and pull it as far up as possible. This will unlock the 24-way connector from the socket on the CAB. CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the ports of HCU or entering the brake tubes. 11. Thoroughly clean all surfaces of the ICU and brake tube nuts. Use only a solvent such as Mopar Brake Parts Cleaner or equivalent to clean the ICU. 12. Remove the brake tubes (4) from the outlet ports on the HCU (Fig. 21) 13. Remove the primary and secondary brake tubes from the inlet ports on the HCU (Fig. 21). 14. Center and prop the steering wheel. 15. Remove the pinch bolt and disconnect the steering shaft coupling. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 5885 16. If equipped, remove the two clips securing silencer to dash seal (Fig. 22). Remove silencer. 17. Remove the three screws securing the dash seal (Fig. 22). Remove seal. 18. Remove the 3 bolts attaching the ICU to its mounting bracket (Fig. 23). 19. Remove ICU from the vehicle through engine compartment. 20. If required, to separating the CAB from the HCU. INSTALLATION - LHD 1. Place the ICU in its bracket below the master cylinder. Start the upper mounting bolt to hold it in place. 2. Inside the vehicle, install the remaining 2 mounting bolts attaching the ICU to the mounting bracket (Fig. 23). Tighten all 3 mounting bolts to a torque of 11 Nm (97 inch lbs.). 3. Install the dash seal and three mounting screws (Fig. 22). 4. If equipped, install the silencer on top of the dash seal (Fig. 22). 5. Connect the steering shaft coupling and install the pinch bolt (Fig. 22). Tighten the pinch bolt to 28 Nm (250 inch lbs.). 6. Remove the steering wheel holder. CAUTION: Because of the flexible section in the primary and secondary brake tubes, the brake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other or other vehicle components when installed. Also, after the brake tubes are installed on the HCU, ensure all spacer clips are reinstalled on the brake tubes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 5886 7. Install the primary and secondary brake tubes into their correct port locations on the HCU valve block (Fig. 21). Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). CAUTION: When installing the chassis brake tubes on the HCU valve block, they must be located correctly in the valve block to ensure proper ABS operation. NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the CAB. 8. Install the (4) chassis brake tubes into their correct port locations on the HCU valve block as shown (Fig. 21). Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). NOTE: Before installing the 24-way connector in the CAB be sure the seal is properly installed in the connector. 9. Install the 24-way connector on the CAB by, first, positioning the 24-way connector in the socket of the CAB and carefully pushing it down as far as possible. Once connector is fully seated by hand into the CAB socket, push down on connector lock. This will pull the connector into the socket of the CAB and lock it in the installed position. 10. Install any routing clips on the brake tubes. 11. Remove the brake pedal holder. 12. Install the speed control servo with its mounting nuts. 13. Connect the wiring harness to the speed control servo. 14. Install the battery tray. 15. Install the screw securing the coolant filler neck to the battery tray. 16. Reconnect the vacuum hose connector at the tank built into the battery tray. 17. Install the battery. 18. Install the battery shield. 19. Remove the brake pedal holder. 20. Connect negative cable back on negative post of the battery. 21. Bleed the Base and ABS brake hydraulic systems. 22. Road test vehicle to ensure proper operation of the base and antilock brake systems. RHD REMOVAL - RHD NOTE: Before proceeding, Refer to BRAKES WARNING. 1. Disconnect the negative (ground) cable from the battery and isolate cable. 2. Using a brake pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the HCU. 3. Raise vehicle. 4. Remove the routing clip attaching the ICU wiring harness to the ICU mounting bracket (Fig. 24). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 5887 CAUTION: Do not apply a 12 volt power source to any terminals of the HCU connector when disconnected. 5. Remove the 24-way connector (Fig. 24) from the CAB. The 24-way connector is removed from the CAB using the following procedure. Grasp the lock on the 24-way connector (Fig. 24) and pull it as far out as possible (Fig. 25). This will raise and unlock the 24-way connector from the socket on the CAB. CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the ports of HCU or entering the brake tubes. 6. Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent to clean the HCU. 7. Remove the brake tubes (6) from the inlet and outlet ports on the HCU. (Fig. 26). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 5888 8. Remove the 3 bolts (Fig. 27) attaching the ICU mounting bracket to the front suspension crossmember. 9. Remove ICU and the mounting bracket as a unit from the vehicle. 10. Remove the 3 bolts (Fig. 28) mounting the ICU to the mounting bracket. Separate the ICU from the mounting bracket. 11. For the procedure on separating and attaching the CAB to the HCU, refer to DISASSEMBLY. INSTALLATION - RHD 1. Install the ICU on the mounting bracket (Fig. 28). Install the 3 bolts (Fig. 28) attaching the ICU to the mounting bracket. Tighten the 3 mounting bolts to a torque of 11 Nm (97 inch lbs.). CAUTION: The ICU mounting bracket to front suspension cradle mounting bolts have a unique corrosion protection coating and a special aluminum washer. For this reason, only the original, or original equipment Mopar replacement bolts can be used to mount the ICU bracket to the front suspension crossmember. 2. Install the ICU and its mounting bracket as an assembly on the front suspension crossmember. Install the 3 bolts attaching the ICU bracket to the crossmember (Fig. 27). Tighten the 3 mounting bolts to a torque of 28 Nm (250 inch lbs.). CAUTION: Because of the flexible section in the primary and secondary brake tubes, and the brake tubes between the HCU and the proportioning valve, the brake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other or other vehicle components when installed. Also, after the brake tubes are installed on the HCU, ensure all spacer clips are reinstalled on the brake tubes. CAUTION: When installing the chassis brake tubes on the HCU valve block, they must be located correctly in the valve block to ensure proper ABS operation. Refer to (Fig. 26) for the correct chassis brake tube locations. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 5889 NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the ICU mounting bracket. 3. Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as shown in (Fig. 26). Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). NOTE: Before installing the 24-way connector in the CAB be sure the seal is properly installed in the connector. 4. Install the 24-way connector (Fig. 24) on the CAB using the following procedure. Position the 24-way connector in the socket of the CAB and carefully push it down as far as possible. When connector is fully seated by hand into the CAB socket, push in the connector lock (Fig. 25). This will pull the connector into the socket of the CAB and lock it in the installed position. NOTE: The CAB wiring harness must be clipped to the ICU mounting bracket. This will ensure the wiring harness is properly routed and does not contact the brake tubes or the body of the vehicle. 5. Clip the cab wiring harness (Fig. 24) to the ICU mounting bracket. 6. Install the routing clips (Fig. 32) on the brake tubes. 7. Lower the vehicle. 8. Connect negative cable back on negative post of the battery. 9. Bleed the base and ABS hydraulic systems. 10. Road test vehicle to ensure proper operation of the base and antilock brake systems. MK25E INTEGRATED CONTROL UNIT (ICU) - MK25E REMOVAL 1. Disconnect the negative (ground) cable from the battery and isolate it. 2. Remove the battery shield and battery. 3. Disconnect the vacuum hose connector at the tank built into the battery tray. 4. Remove the screw securing the engine coolant filler neck to the battery tray. 5. Remove the battery tray. 6. Using a brake pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This will prevent brake fluid from draining out of the master cylinder once the brake tubes are removed from the ICU. 7. Disconnect the wiring harness connector from the speed control servo. 8. Remove the speed control servo mounting nuts and move the servo out of the way. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 5890 9. Disconnect the 47-way connector from the antilock brake module (ABM) by depressing the tabs on each side of the connector cover (Fig. 34), then pulling outward and upward on the lower half of the cover until it locks into position pointing straight outward. The connector can then be pulled straight outward off the ABM (Fig. 35). CAUTION: Before removing the brake tubes from the ICU, the ICU must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the ports of ICU or entering the brake tubes. 10. Thoroughly clean all surfaces of the ICU and brake tube nuts. Use only a solvent such as Mopar Brake Parts Cleaner or equivalent to clean the ICU. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 5891 11. Remove the primary and secondary brake tubes from the inlet ports on the ICU (Fig. 36). 12. Remove the four chassis brake tubes from the outlet ports on the ICU (Fig. 37). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 5892 13. Remove the single mounting bolt (Fig. 38), then slide the mounting pins (on bottom of ICU) out of the grommets in the bracket. Remove the ICU. 14. If the ABM and HCU need to be separated, Refer to ABS/HYDRAULIC/MECHANICAL/ICU (INTEGRATED CONTROL UNIT). INSTALLATION 1. Place the ICU in its bracket below the master cylinder by first inserting the mounting pins on the bottom of the ICU into the grommets mounted in the bracket, then install the single mounting bolt on the side (Fig. 38). Tighten the mounting bolt to 11 Nm (97 inch lbs.) torque. 2. Install the four chassis brake tubes into their correct port locations on the ICU as shown (Fig. 37). Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). CAUTION: Because of the flexible section in the primary and secondary brake tubes, the brake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other or other vehicle components when installed. Also, after the brake tubes are installed on the ICU, ensure all spacer clips are reinstalled on the brake tubes. 3. Install the primary and secondary brake tubes into their correct port locations on the ICU (Fig. 36). Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). 4. Install any routing clips on the brake tubes. 5. With connector cover completely open (Fig. 35), install 47-way wiring connector into socket of the ABM and close cover, locking connector in place. 6. Install the speed control servo with its mounting nuts. 7. Connect the wiring harness to the speed control servo. 8. Install the battery tray. 9. Install the screw securing the coolant filler neck to the battery tray. 10. Reconnect the vacuum hose connector at the tank built into the battery tray. 11. Install the battery and battery shield. 12. Remove the brake pedal holder. 13. Connect the negative cable on the battery negative post. 14. Hook up a scan tool to initialize ABM and check for any faults. 15. Fill master cylinder with clean, fresh Mopar Brake Fluid or equivalent, then bleed base brakes and ABS. 16. Road test vehicle to ensure proper operation of brakes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 5893 Hydraulic Control Assembly - Antilock Brakes: Service and Repair ICU - Disassembly and Assembly MK20E DISASSEMBLY - ICU 1. Remove the ICU from the vehicle. 2. Disconnect the pump/motor wiring harness from the CAB (Fig. 29). 3. Remove the 4 bolts (Fig. 30) attaching the CAB to the HCU. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 5894 4. Remove the CAB from the HCU (Fig. 31). ASSEMBLY - ICU 1. Install the CAB (Fig. 31) on the HCU. 2. Install the 4 bolts mounting the CAB (Fig. 30) to the HCU. Tighten the CAB mounting bolts to a torque of 2 Nm (17 inch lbs.). 3. Plug the pump/motor wiring harness into the CAB. 4. Install the ICU in the vehicle and bleed the base and ABS hydraulic systems. MK25E INTEGRATED CONTROL UNIT (ICU) - MK25E DISASSEMBLY 1. If not equipped with traction control, remove the three screws attaching the ABM to the HCU (Fig. 39). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 5895 2. If equipped with traction control, remove the four screws attaching the ABM to the HCU (Fig. 40). 3. Separate the ABM from the HCU (Fig. 41). ASSEMBLY 1. Clean any debris off the mating surfaces of the HCU and ABM. CAUTION: When installing new O-rings or solenoid valve stem seals, do not use any type of lubricant. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 5896 2. If the seals on the components are not new, they must be replaced. Each of the solenoid valve stem seals must be replaced (Fig. 42); do not reuse solenoid valve stem seals. The pump/motor connector O-ring should also be replaced if not new (Fig. 43). 3. Align components and install the ABM on the HCU (Fig. 41). 4. If not equipped with traction control, install the three screws attaching the ABM to the HCU (Fig. 39). Tighten the mounting screws to 2 Nm (17 inch lbs.) torque. 5. If equipped with traction control, install the four screws attaching the ABM to the HCU (Fig. 40). Tighten the mounting screws to 2 Nm (17 inch lbs.) torque. 6. Install the ICU in the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Component Locations > Page 5904 Traction Control Switch: Connector Locations Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Component Locations > Page 5905 Steering Column Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 5906 Traction Control Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 5907 Traction Control Switch: Testing and Inspection TRACTION CONTROL SWITCH DIAGNOSIS AND TESTING - TRACTION CONTROL SWITCH 1. Remove lower steering column shroud. 2. Disconnect traction control switch harness from column harness (Fig. 5). 3. Using an ohmmeter, check for continuity between pins 1 and 2. With the switch actuated, there should be continuity between the two pins. With the switch off, there should be no continuity. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 5908 Traction Control Switch: Service and Repair TRACTION CONTROL SWITCH REMOVAL The traction control switch is located in the upper shroud. Refer to Steering. INSTALLATION The traction control switch is located in the upper shroud. Refer to Steering. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Brakes - Rear Wheel Speed Sensor Replacement Guidelines Wheel Speed Sensor: Technical Service Bulletins Brakes - Rear Wheel Speed Sensor Replacement Guidelines NUMBER: 05-004-04 REV. A GROUP: Brakes DATE: December 3, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-004-04, DATED SEPTEMBER 2, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. SUBJECT: Anti-lock Brake Rear Wheel Speed Sensor Replacement MODELS: **2001 - 2005 (RG) Chrysler Voyager** 2001 - 2005 (RS) Town & Country/Caravan/Voyager NOTE: This bulletin applies to non-all wheel drive vehicles equipped with anti-lock brakes (sales code BGF). PARTS REQUIRED: DISCUSSION: When replacing a rear wheel speed sensor, upon disassembly, inspect for moisture on the sensor and inside the bearing cap. If moisture is present, the moisture must be dried out prior to reassembly, or the new sensor may be damaged. When installing a replacement wheel speed sensor, be sure to lubricate the sensor 0-ring and the sensor head completely, with Mopar wheel bearing grease, p/n 05083149AA, before installation. NOTE: It is important that only Mopar, p/n 05083149AA, Wheel Bearing Grease, or M56560 equivalent, be used for this application. No other lubricant may be substituted. Other lubricants may cause sensor damage. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 5913 Wheel Speed Sensor: Specifications TONE WHEEL RUNOUT WHEEL SPEED SENSOR AIR GAP Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations WHEEL SPEED SENSORS FRONT REAR WHEEL SPEED SENSOR CONNECTORS FRONT Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 5916 REAR Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 5917 Wheel Speed Sensor: Connector Locations Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 5918 Left Fender Shield Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 5919 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 5920 Left Rear Body Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 5921 Right Quarter Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 5922 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor Left Rear Wheel Speed Sensor Right Front Wheel Speed Sensor Right Rear Wheel Speed Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 5923 Wheel Speed Sensor: Description and Operation ABS SWITCHES/SENSORS Wheel Speed Sensors and Tone Wheels: One active wheel speed sensor (WSS) is located at each wheel. The sensors use an electronic principle known as magneto-resistive to help increase performance, durability and low speed accuracy. The sensors convert wheel speed into a small digital signal. A toothed gear tone wheel serves as the trigger mechanism for each sensor. The CAB/ABM sends 12 volts to power an Integrated Circuit 01C) in the sensor. The IC supplies a constant 7 mA signal to the CAB/ABM. The relationship of the tooth on the tone wheel to the permanent magnet in the sensor, signals the IC of the sensor to toggle a second 7 mA power supply on or off. The output of the sensor, sent to the CAB/ ABM, is a DC voltage signal with changing voltage and current levels. The CAB/ABM monitors the changing amperage (digital signal) from each wheel speed sensor. The resulting signal is interpreted by the CAB/ABM as the wheel speed. Because of internal circuitry, correct wheel speed sensor function cannot be determined by a continuity or resistance check through the sensor. Correct antilock system operation is dependent on tone wheel speed signals from the wheel speed sensors. The vehicle's wheels and tires should all be the same size and type to generate accurate signals. In addition, the tires should be inflated to the recommended pressure for optimum system operation. Variation in wheel and tire size or significant variations in inflation pressure can produce inaccurate wheel speed signals; however, the system will continue to function when using the correct factory mini-spare. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Page 5924 Wheel Speed Sensor: Testing and Inspection TONE WHEEL INSPECTION - TONE WHEEL NOTE: Rear tone wheels for front-wheel-drive vehicles are sealed within the hub and bearing assembly and cannot be inspected or replaced. Replacement of the hub and bearing is necessary. Tone wheels can cause erratic wheel speed sensor signals. Inspect tone wheels for the following possible causes. ^ missing, chipped, or broken teeth ^ contact with the wheel speed sensor ^ wheel speed sensor to tone wheel alignment ^ wheel speed sensor to tone wheel clearance ^ excessive tone wheel runout ^ tone wheel loose on its mounting surface If a front tone wheel is found to need replacement, the drive shaft must be replaced. No attempt should be made to replace just the tone wheel. If wheel speed sensor to tone wheel contact is evident, determine the cause and correct it before replacing the wheel speed sensor or tone wheel. Check the gap between the speed sensor head and the tone wheel to ensure it is within specifications. Excessive wheel speed sensor runout can cause erratic wheel speed sensor signals. Refer to SPECIFICATIONS for the maximum allowed tone wheel runout. If tone wheel runout is excessive, determine if it is caused by a defect in the driveshaft assembly or hub and bearing. Replace as necessary. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Replacement of entire component is necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front FRONT WHEEL SPEED SENSOR REMOVAL 1. Raise vehicle. 2. Remove the tire and wheel assembly. 3. Remove the sensor cable routing clamp screws. CAUTION: When disconnecting the wheel speed sensor from vehicle wiring harness, be careful not to damage pins on connector 4. Remove speed sensor cable grommets from intermediate bracket on strut. 5. Disconnect speed sensor cable from vehicle wiring harness behind fender well shield. 6. Remove the wheel speed sensor head mounting bolt (Fig. 1). 7. Remove sensor head from steering knuckle. If sensor has seized due to corrosion, DO NOT USE PLIERS ON SENSOR HEAD. Use a hammer and a punch and tap edge of sensor ear, rocking the sensor side-to-side until free. 8. Remove front wheel speed sensor from vehicle. INSTALLATION CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as shown may result in contact with moving parts and over extension of cables, resulting in an open circuit. 1. Connect the front wheel speed sensor cable to the vehicle wiring harness connector. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector. 2. Install the bolts attaching the routing clamps to the body of the vehicle. Tighten the bolts to a torque of 14 Nm (125 inch lbs.). 3. Insert speed sensor cable grommets into intermediate bracket on strut. 4. Install the wheel speed sensor head mounting bolt (Fig. 1). Tighten the bolt to a torque of 13 Nm (115 inch lbs.) 5. Install the wheel and tire assembly on vehicle. 6. Lower vehicle. 7. Road test vehicle to ensure proper operation of the base and ABS brake systems. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5927 Wheel Speed Sensor: Service and Repair Rear Rear Wheel Speed Sensor - FWD REAR WHEEL SPEED SENSOR - FWD REMOVAL 1. Raise vehicle. CAUTION: When disconnecting speed sensor cable from vehicle wiring harness be careful not to damage pins on the electrical connectors. Also, inspect connectors for any signs of previous damage. 2. Remove grommet from floor pan of vehicle and disconnect speed sensor cable connector from vehicle wiring harness (Fig. 2). CAUTION: When removing rear wheel speed sensor cable from routing clips, be sure not to damage the routing clips. Routing clips that are molded onto the brake hose will require replacement of the brake hose if damaged during removal or installation of the speed sensor cable. 3. Carefully remove speed sensor cable from press-in routing clips (Fig. 3). 4. Remove bolt securing metal routing clip to rear of axle and remove sensor cable from metal clip (Fig. 3). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5928 5. Remove secondary (yellow) retaining clip at rear of wheel speed sensor head (Fig. 4). 6. Push up on metal retaining clip (Fig. 4) until it bottoms. This will release wheel speed sensor head from hub and bearing. While holding metal clip up, pull back on wheel speed sensor head removing it from hub and bearing. 7. Remove wheel speed sensor assembly from vehicle. INSTALLATION CAUTION: Proper installation of wheel speed sensor cable is critical to continued system operation. Be sure that cable is installed in routing retainers/clips. Failure to install cable in retainers may result in contact with moving parts or over extension of cable, resulting in an open circuit. CAUTION: It is important that only Mopar Wheel Bearing Grease be used for the following step application. Other lubricants may cause sensor failure. 1. Lubricate the sensor O-ring with Mopar Wheel Bearing Grease before installation into the Hub And Bearing. If not lubricated, an improper seal may result due to rolling of the O-ring. 2. If metal sensor retaining clip is not in the neutral installed position on hub and bearing cap, install from the bottom, if necessary, and push clip upward until it snaps into position. 3. Install wheel speed sensor head into rear of hub and bearing aligning index tab with the notch in the top of the mounting hole. Push the sensor in until it snaps into place on the metal retaining clip. 4. Install secondary (yellow) retaining clip over wheel speed sensor head and engage the tabs on each side. 5. Route sensor cable under leaf spring along rear of axle. Install speed sensor cable into routing clips on rear brake flex hose (Fig. 3). 6. Install cable into metal routing clip and attach it to the rear axle with mounting bolt (Fig. 3). Tighten mounting bolt to 16 Nm (140 inch lbs.). 7. Connect wheel speed sensor cable to vehicle wiring harness (Fig. 2). Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector. 8. Install speed sensor cable grommet into hole in floor pan making sure grommet is fully seated into hole. 9. Lower vehicle. 10. Road test vehicle to ensure proper operation of the base and ABS braking systems. Rear Wheel Speed Sensor - AWD REAR WHEEL SPEED SENSOR - AWD REMOVAL 1. Raise vehicle. CAUTION: When disconnecting speed sensor cable from vehicle wiring harness be careful not to damage pins on the electrical connectors. Also, inspect connectors for any signs of previous damage. 2. Remove grommet from floor pan of vehicle and disconnect speed sensor cable connector from vehicle wiring harness. CAUTION: When removing rear wheel speed sensor cable from routing clips, be sure not to damage the routing clips. Routing clips that are molded onto the brake hose will require replacement of the brake hose if damaged during removal or installation of the speed sensor cable. 3. Carefully remove speed sensor cable from press-in routing clips along brake hose and tubing. 4. Remove bolt securing wheel speed sensor cable metal clip to rear of axle. Remove metal clip from cable if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 5929 CAUTION: If speed sensor head has seized due to corrosion, do not use pliers on speed sensor head in an attempt to remove it. Use a hammer and a punch and tap mounting flange edge side-to-side, rocking the sensor until free. 5. Remove wheel speed sensor head attaching bolt. 6. Remove wheel speed sensor head from the axle, and remove sensor from vehicle. INSTALLATION CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as indicated may result in contact with moving parts or over-extension of cables, resulting in an open circuit. 1. Install wheel speed sensor head in axle flange. CAUTION: Prior to installing the speed sensor head attaching bolt, the plastic anti-rotation pin must be fully seated into the bearing flange. 2. Install wheel speed sensor head attaching bolt. Tighten bolt to a torque 10 Nm (90 inch lbs.). 3. Check the air gap between the face of the wheel speed sensor and the top surface of the tone wheel. CAUTION: When installing wheel speed sensor cable in the routing clips on rear brake flex hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will require replacement of the brake hose if damaged. 4. Install speed sensor cable under leaf spring onto brake hose and tubing utilizing routing clips to secure it in place. 5. Install metal routing clip on speed sensor cable and mount it to rear of axle with mounting bolt. Tighten mounting bolt to 16 Nm (140 inch lbs.). 6. Connect wheel speed sensor cable to vehicle wiring harness. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector. 7. Install speed sensor cable grommet into the floor pan, being sure the grommet is fully seated into the access hole. 8. Lower vehicle. 9. Road test vehicle to ensure proper operation of the base and ABS braking systems. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE - MASTER CYLINDER BLEEDING CAUTION: When clamping master cylinder in vise, only clamp master cylinder by its mounting flange. Do not clamp master cylinder piston rod, reservoir, seal or body. 1. Clamp master cylinder in a vise. NOTE: Use correct bleeder tubes when bleeding master cylinder. Master cylinder outlet ports vary in size and type depending on whether master cylinder is for a vehicle equipped with ABS or not. ABS equipped master cylinders require the additional use of ISO style flare adapters supplied in Special Tool Package 8822 to be used in conjunction with Bleeder Tubes, Special Tool Package 8358. 2. Attach special tools for bleeding master cylinder in the following fashion: a. For non-ABS control equipped master cylinders, thread a Bleeder Tube, Special Tool 8358-1, into each outlet port. Tighten each tube to 17 Nm (145 inch lbs.) torque. Flex bleeder tubes and place open ends into mouth of fluid reservoir as far down as possible (Fig. 47). b. For ABS equipped master cylinders, thread one Adapter, Special Tool 8822-2, in each outlet port. Tighten Adapters to 17 Nm (145 inch lbs.) torque. Next, thread a Bleeder Tube, Special Tool 8358-1, into each Adapter. Tighten each tube to 17 Nm (145 inch lbs.) torque. Flex bleeder tubes and place open ends into mouth of fluid reservoir as far down as possible (Fig. 47). NOTE: Make sure open ends of bleeder tubes stay below surface of brake fluid once reservoir is filled to proper level. 3. Fill brake fluid reservoir with Mopar brake fluid or equivalent conforming to DOT 3 (DOT 4 and DOT 4+ are acceptable) specifications. Make sure fluid level is above tips of bleeder tubes in reservoir to ensure no air is ingested during bleeding. 4. Using a wooden dowel as a pushrod (Fig. 47), slowly depress master cylinder pistons, then release pressure, allowing pistons to return to released position. Repeat several times until all air bubbles are expelled. Make sure fluid level stays above tips of bleeder tubes in reservoir while bleeding. 5. Remove bleeder tubes from master cylinder outlet ports, then plug outlet ports and install fill cap on reservoir. 6. Remove master cylinder from vise. 7. Install master cylinder on vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5934 Brake Bleeding: Service and Repair Base Brake System STANDARD PROCEDURE - BASE BRAKE BLEEDING NOTE: This bleeding procedure is only for the vehicle's base brakes hydraulic system. CAUTION: Before removing the master cylinder cover, thoroughly clean the cover and master cylinder fluid reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid reservoir. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic system. ^ Left Rear Wheel ^ Right Front Wheel ^ Right Rear Wheel ^ Left Front Wheel NOTE: When bleeding the brake system, some air may be trapped in the brake lines or valves far upstream, as much as ten feet from the bleeder screw (Fig. 1). Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. The brakes may be manually bled or pressure bled. MANUAL BLEEDING PROCEDURE NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper. NOTE: To adequately bleed the brakes using the manual bleeding procedure the rear brakes must be correctly adjusted. Prior to the manual bleeding of the brake hydraulic system, correctly adjust the rear brakes. 1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened. 2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at least 1 full turn. When the bleeder screw opens the brake pedal will drop all the way to the floor. CAUTION: "Just cracking" the bleeder screw often restricts fluid flow, allowing only a slow, weak fluid discharge of fluid. This practice will NOT get all the air out. Make sure the bleeder is opened at least 1 full turn when bleeding. 3. Release the brake pedal only after the bleeder screw is closed. 4. Repeat steps 1 through 3, four or five times, at each bleeder screw in the proper sequence. This should pass a sufficient amount of fluid to expel all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 5. Check pedal travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Continue to bleed system as necessary. 6. Perform a final adjustment of the rear brake shoes (when applicable), then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. PRESSURE BLEEDING PROCEDURE CAUTION: Use bleeder tank Special Tool C-3496-B or equivalent with Adapter, Special Tool 6921, to pressurize the hydraulic system for bleeding. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5935 Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. 1. Install the Adapter Master Cylinder Pressure Bleed Cap, Special Tool 6921 on the fluid reservoir of the master cylinder (Fig. 2). Attach the fluid hose from the pressure bleeder to the fitting on Special Tool 6921. 2. Attach a clear plastic hose to the bleeder screw at one wheel and feed the hose into a clear jar containing fresh brake fluid. 3. Open the left rear wheel bleeder screw at least one full turn or more to obtain an adequate flow of brake fluid. CAUTION: "Just cracking" the bleeder screw often restricts fluid flow, allowing only a slow, weak fluid discharge of fluid. This practice will NOT get all the air out. Make sure the bleeder is opened at least 1 full turn when bleeding. 4. After 4 to X ounces of brake fluid has been bled through the hydraulic system, and an air-free flow is maintained in the hose and jar, this will indicate a good bleed of the hydraulic system has been obtained. 5. Repeat the procedure at all the other remaining bleeder screws. 6. Check pedal travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 7. Perform a final adjustment of the rear brake shoes (when applicable), then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 5936 Brake Bleeding: Service and Repair Antilock Brake System STANDARD PROCEDURE - ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS though, particularly the ICU (HCU), should only need to be bled when the HCU is replaced or removed from the vehicle. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Under most circumstances that require the bleeding of the brakes hydraulic system, only the base brake hydraulic system needs to be bled. When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the scan tool to the Data Link Connector. The connector is located under the lower steering column cover to the left of the steering column. 3. Using the scan tool, check to make sure the CAB (MK20e) or ABM (Mk25e) does not have any fault codes stored. If it does, clear them using the scan tool. WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY FROM YOURSELF AND THE PAINTED SURFACES OF THE VEHICLE. BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN OPENED. 4. Bleed the base brake system using the standard pressure or manual bleeding procedure. 5. Using the scan tool, select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When the scan tool displays TEST COMPLETED, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. 7. Fill the master cylinder reservoir to the full level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation Brake Warning Indicator: Description and Operation ABS AND BRAKE WARNING INDICATORS The amber ABS warning indicator is located in the instrument cluster. It is used to inform the driver that the antilock function has been turned off. The ABS warning indicator is controlled by the CAB/ABM. The CAB/ABM controls the lamp with a command over the PCI bus. The ABS Warning Indicator will remain lit during every key cycle until a circuit or component fault is repaired and the CAB/ABM no longer detects the fault. After repair of a sensor signal fault or a pump motor fault, the CAB/ABM must sense all four wheels at 25 km/h (15 mph) before it will extinguish the ABS and TCS Indicator. The Instrument Cluster will illuminate the ABS Warning Indicator if it loses communication with the CAB/ABM. The red BRAKE warning indicator is also located in the instrument cluster. It can be activated in several ways. Application of the parking brake or a low fluid signal from the fluid level switch located in the master cylinder reservoir will cause the indicator to come on. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Brake Caliper DISC BRAKE CALIPER - FRONT REMOVAL REMOVAL - FRONT DISC BRAKE CALIPER (CONTINENTAL TEVES BRAKES) 1. Depress the brake pedal past its first inch of travel and hold it in this position using a brake pedal depressor (holding) tool. This is done to isolate the master cylinder from the brake hydraulic system disallowing the brake fluid to completely drain out of the brake fluid reservoir. 2. Raise the vehicle. 3. Remove front wheel and tire assembly. 4. Remove the banjo bolt connecting the brake hose to the brake caliper. There are two washers (one on each side of the brake hose fitting) that will come off with the banjo bolt. Discard these washers. 5. Remove the 2 caliper guide pin bolts. 6. Remove the brake caliper from the adapter. REMOVAL - FRONT DISC BRAKE CALIPER (TRW BRAKES) 1. Using a brake pedal holding tool, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir when the lines are opened. 2. Raise the vehicle. 3. Remove the front tire and wheel assembly. 4. Remove the banjo bolt connecting the brake hose to the brake caliper (Fig. 31). There are two washers (one on each side of the flex hose fitting) that will come off with the banjo bolt. Discard the washers. 5. Remove the two brake caliper guide pin bolts (Fig. 31). 6. Remove the disc brake caliper from the disc brake adapter. DISASSEMBLY DISASSEMBLY - CALIPER GUIDE PIN BUSHINGS (CONTINENTAL TEVES BRAKES) Before disassembling the brake caliper, clean and inspect it. 1. Using your fingers, collapse one side of the rubber guide pin bushing. Pull the guide pin bushing out the other side of the brake caliper mounting boss. 2. Repeat this procedure on the remaining bushing. DISASSEMBLY - CALIPER PISTON AND SEAL WARNING: UNDER NO CONDITION SHOULD HIGH PRESSURE AIR EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. NOTE: Before disassembling the brake caliper, clean and inspect it. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5945 NOTE: The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of the vehicle's brake system. 1. Following the removal procedure in DISC BRAKE SHOES, remove the caliper from the brake rotor and hang the assembly on a wire hook away from rotor and body of the vehicle so brake fluid cannot get on these components. Remove the brake shoes, and place a small piece of wood between the piston and caliper fingers. 2. Carefully depress the brake pedal to hydraulically push piston out of its bore. Once completed, apply and hold down the brake pedal to any position beyond the first inch of pedal travel using a brake pedal holding tool. This will prevent the fluid in the master cylinder reservoir from completely draining out. 3. Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 4. Mount the caliper in a vise equipped with protective jaws. 5. Remove the piston dust boot from the caliper and discard. NOTE: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. 6. Using a soft tool such as a plastic trim stick, work the piston seal out of its groove in caliper piston bore (Fig. 32). Discard the old seal. 7. Clean the piston bore and drilled passage ways using alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 8. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. CLEANING - CALIPER WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. INSPECTION - CALIPER Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5946 Inspect the disc brake caliper for the following: ^ Brake fluid leaks in and around boot area and inboard lining ^ Ruptures, brittleness or damage to the piston dust boot ^ Damaged, dry or brittle guide pin dust boots If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. ASSEMBLY ASSEMBLY - CALIPER GUIDE PIN BUSHINGS (CONTINENTAL TEVES BRAKES) 1. Fold the guide pin bushing in half lengthwise. NOTE: To avoid damage to the bushing, do not use a sharp object to install the guide pin bushing. 2. Insert the folded bushing into the caliper mounting boss using your fingers from the rear of the caliper. 3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing. The bushing flanges should be seated evenly on both sides of the bushing hole. 4. Lubricate inside surfaces of bushing using Mopar Dielectric Grease or equivalent. 5. Repeat the procedure for remaining bushing. ASSEMBLY - CALIPER PISTON AND SEAL NOTE: Never use an old piston seal. 1. Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore. The seal should be started at one area of the groove and gently worked around and into the groove (Fig. 33) using only your clean fingers to seat it. 2. Coat the new piston boot with clean brake fluid. 3. Position the dust boot over the piston after coating it with brake fluid. CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5947 4. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore (Fig. 34). 5. Position the dust boot into the counterbore of the caliper assembly piston bore. 6. Using a hammer and Installer, Special Tool C-4689 or C-4842 (depending on piston size), and Handle, Special Tool C-4171, drive the boot into the counterbore of the caliper as necessary (Fig. 35). 7. Reinstall the caliper on the vehicle and bleed the brakes as necessary. INSTALLATION INSTALLATION - FRONT DISC BRAKE CALIPER (CONTINENTAL TEVES BRAKES) CAUTION: TRW and Continental Teves brake calipers are not interchangeable. Each caliper is specifically designed for the unique brake system. If calipers are interchanged, improper performance, noise and increased stopping distance can occur. 1. Completely retract the caliper piston back into piston bore of the caliper. Use a C-clamp to retract the piston if necessary. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5948 CAUTION: Use care when installing the brake caliper assembly onto the steering knuckle, so that the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. 2. Carefully position the brake caliper and shoes over the brake rotor and adapter. 3. Install the caliper guide pin bolts and tighten to a torque of 35 Nm (26 ft. lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts. 4. Install the anti-rattle clip on the outboard side of the caliper. Start the clip into the holes on the caliper, then stretch the clip legs past the abutments on the caliper adapter. CAUTION: When connecting the brake hose to the caliper, install new brake hose to caliper special copper washers. 5. Install the brake hose on the caliper. To do this, first place one NEW special fitting washer on each side of the hose fitting, then slide the banjo bolt through the fitting. Next, thread the banjo bolt into the threaded port on the rear of the brake caliper. Tighten the banjo bolt to a torque of 47 Nm (35 ft. lbs.). 6. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification, then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 7. Lower the vehicle. 8. Remove the brake pedal depressor (holding) tool. 9. Bleed the hydraulic brake circuit to the brake caliper. 10. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. INSTALLATION - FRONT DISC BRAKE CALIPER (TRW BRAKES) CAUTION: TRW and Continental Teves brake calipers are not interchangeable. Each caliper is specifically designed for the unique brake system. If calipers are interchanged, improper performance, noise and increased stopping distance can occur. 1. Completely retract the caliper piston back into the bore of the caliper. Use a C-clamp to retract the piston if necessary. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston. CAUTION: Use care when installing the caliper onto the disc brake adapter to avoid damaging the boots on the caliper guide pins. 2. Install the disc brake caliper over the brake shoes on the brake caliper adapter. 3. Align the caliper guide pin bolt holes with the guide pins. Install the caliper guide pin bolts and tighten them to a torque of 35 Nm (26 ft. lbs.) (Fig. 31). 4. Install the banjo bolt connecting the brake hose to the brake caliper (Fig. 31). Install NEW copper washers on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to a torque of 47 Nm (35 ft. lbs.). 5. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Remove the brake pedal holding tool. 8. Bleed the caliper as necessary. 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes. Disc Brake Caliper Adapter DISC BRAKE CALIPER ADAPTER REMOVAL - FRONT DISC BRAKE CALIPER ADAPTER 1. Raise vehicle. 2. Remove front wheel and tire assembly, disc brake caliper and brake shoes. 3. Remove two bolts fastening adapter to steering knuckle, then remove disc brake caliper adapter. INSTALLATION - FRONT DISC BRAKE CALIPER ADAPTER 1. Place adapter over brake rotor and align adapter mounting holes to knuckle. CAUTION: Adapter mounting bolts have a special Dacromet coating applied to resist corrosion. If mounting bolts need to be replaced, use only Mopar replacement parts. 2. Install adapter mounting bolts and tighten to 169 Nm (125 ft. lbs.) torque. 3. Install brake shoes, disc brake caliper and wheel and tire assembly. 4. Lower vehicle. 5. Pump the brake pedal several times to set the pads to the brake rotor. 6. Check and adjust brake fluid level as necessary. Disc Brake Caliper Guide Pins DISC BRAKE CALIPER GUIDE PINS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5949 REMOVAL - DISC BRAKE CALIPER GUIDE PINS (TRW BRAKES) 1. Raise the vehicle. 2. Remove the front tire and wheel assembly. 3. Remove the two brake caliper guide pin bolts (Fig. 42). 4. Remove the disc brake caliper from the disc brake caliper adapter and hang it out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this. 5. Remove the guide pins and boots from the adapter as shown (Fig. 43). INSTALLATION - DISC BRAKE CALIPER GUIDE PINS (TRW BRAKES) 1. Lubricate the guide pins and inside the boots with the packet supplied with the service kit, Sytheso GLK-1 lubricant or equivalent. 2. Install the guide pins and boots in the adapter as shown (Fig. 43). The boots have grooves built into their inner lips to fit onto the pins and adapter. CAUTION: Use care when installing the caliper onto the disc brake adapter to avoid damaging the boots on the caliper guide pins. 3. Install the disc brake caliper over the brake shoes on the brake caliper adapter. 4. Align the caliper guide pin bolt holes with the guide pins. Install the caliper guide pin bolts and tighten them to a torque of 35 Nm (26 ft. lbs.) (Fig. 42). 5. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Pump the brake pedal several times before moving the vehicle to set the shoes to the brake rotor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5950 Brake Caliper: Service and Repair Rear DISC BRAKE CALIPER REAR REMOVAL - REAR DISC BRAKE CALIPER NOTE: Handling of the rotor and caliper, must be done in such a way as to avoid damage to the rotor and scratching or nicking of lining on the brake shoes. 1. Depress the brake pedal past its first inch of travel and hold it in this position using a brake pedal depressor (holding) tool. This is done to isolate the master cylinder from the brake hydraulic system disallowing the brake fluid to completely drain out of the brake fluid reservoir. 2. Raise the vehicle. 3. Remove rear wheel and tire assembly from vehicle. 4. Remove the banjo bolt connecting the brake hose to the brake caliper. There are two washers (one on each side of the brake hose fitting) that will come off with the banjo bolt. Discard these washers. 5. Remove the disc brake caliper to adapter guide pin bolts (Fig. 36). 6. Remove rear caliper from adapter using the following procedure. First rotate front of caliper up from the adapter. Then pull the rear of the caliper and the outboard brake shoe anti-rattle clip out from under the rear abutment on the adapter (Fig. 37). 7. If the brake rotor requires removal, it can now be removed by first removing the retainer clips from the wheel mounting studs, then pulling the rotor straight off the studs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5951 DISASSEMBLY - CALIPER PISTON AND SEAL WARNING: UNDER NO CONDITION SHOULD HIGH PRESSURE AIR EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. NOTE: Before disassembling the brake caliper, clean and inspect it. NOTE: The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of the vehicle's brake system. 1. Following the removal procedure in DISC BRAKE SHOES, remove the caliper from the brake rotor and hang the assembly on a wire hook away from rotor and body of the vehicle so brake fluid cannot get on these components. Remove the brake shoes, and place a small piece of wood between the piston and caliper fingers. 2. Carefully depress the brake pedal to hydraulically push piston out of its bore. Once completed, apply and hold down the brake pedal to any position beyond the first inch of pedal travel using a brake pedal holding tool. This will prevent the fluid in the master cylinder reservoir from completely draining out. 3. Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 4. Mount the caliper in a vise equipped with protective jaws. 5. Remove the piston dust boot from the caliper and discard. NOTE: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. 6. Using a soft tool such as a plastic trim stick, work the piston seal out of its groove in caliper piston bore (Fig. 38). Discard the old seal. 7. Clean the piston bore and drilled passage ways using alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 8. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. CLEANING - CALIPER WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5952 ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. INSPECTION - CALIPER Inspect the disc brake caliper for the following: ^ Brake fluid leaks in and around boot area and inboard lining ^ Ruptures, brittleness or damage to the piston dust boot ^ Damaged, dry or brittle guide pin dust boots If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. ASSEMBLY - CALIPER PISTON AND SEAL NOTE: Never use an old piston seal. 1. Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore. The seal should be started at one area of the groove and gently worked around and into the groove (Fig. 39) using only your clean fingers to seat it. 2. Coat the new piston boot with clean brake fluid. 3. Position the dust boot over the piston after coating it with brake fluid. CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5953 4. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore (Fig. 40). 5. Position the dust boot into the counterbore of the caliper assembly piston bore. 6. Using a hammer and Installer, Special Tool C-4689 or C-4842 (depending on piston size), and Handle, Special Tool C-4171, drive the boot into the counterbore of the caliper as necessary (Fig. 41). 7. Reinstall the caliper on the vehicle and bleed the brakes as necessary. INSTALLATION - REAR DISC BRAKE CALIPER 1. Completely retract caliper piston back into piston bore of the caliper. 2. If removed, install the brake rotor on the hub, making sure it is squarely seated on the face of the hub. CAUTION: Use care when installing the caliper assembly onto the adapter, so the caliper guide pin bushings do not get damaged by the mounting bosses. 3. Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse procedure for removal (Fig. 37). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5954 CAUTION: When installing guide pin bolts extreme caution should be taken not to cross-thread the caliper guide pin bolts. 4. Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 35 Nm (26 ft. lbs.). CAUTION: When connecting the brake hose to the caliper, install new brake hose to caliper special washers. 5. Install the brake hose on the caliper. To do this, first place one NEW special copper washer on each side of the hose fitting, then slide the banjo bolt through the fitting. Next, thread the banjo bolt into the threaded port on the rear of the brake caliper. Tighten the banjo bolt to a torque of 47 Nm (35 ft. lbs.). 6. Install the wheel and tire assembly. 7. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 8. Lower the vehicle. 9. Remove the brake pedal depressor (holding) tool. 10. Bleed the hydraulic brake circuit to the brake caliper. 11. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Brake Pad - For front disc brake shoes, when a set of brake shoes are worn to a thickness of approximately 7.95 mm (5/16 inch), they should be replaced. - For rear disc brake shoes, when a set of brake shoes are worn to a thickness of approximately 7.0 mm (9/32 inch), they should be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front REMOVAL - FRONT DISC BRAKE SHOES (CONTINENTAL TEVES BRAKES) 1. Raise the vehicle. 2. Remove both front wheel and tire assemblies. 3. Begin on one side of the vehicle. 4. Remove the anti-rattle clip from the outboard side of the caliper and adapter. 5. Remove the two caliper guide pin bolts. 6. Remove caliper from caliper adapter and brake rotor. CAUTION: Supporting weight of caliper by the flexible brake fluid hose can damage the hose. 7. Using wire or cord, hang the caliper from the front strut assembly (Fig. 11). Support the caliper firmly to prevent weight of caliper from being supported by the brake fluid hose. 8. Remove the outboard brake shoe from the caliper adapter. 9. Pull the inboard brake shoe away from the caliper piston until the retaining clip on shoe is free from the cavity in the caliper piston (Fig. 12). 10. Repeat the above procedure on other side of the vehicle. REMOVAL - FRONT DISC BRAKE SHOES (TRW BRAKES) 1. Raise the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5960 NOTE: Perform Step 2 through Step 5 on each side of the vehicle. 2. Remove the front tire and wheel assembly. 3. Remove the two brake caliper guide pin bolts (Fig. 13). 4. Remove the disc brake caliper from the disc brake adapter and hang out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this. 5. Remove the brake shoes from the disc brake caliper adapter. CLEANING - DISC BRAKE SHOES WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. INSPECTION - DISC BRAKE SHOES Visually inspect brake shoes (pads) for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators on the shoes (if equipped) and the brake rotors. If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the disc brake shoes from the calipers. Measure each brake shoe. The combined brake shoe and its lining material thickness should be measured at its thinnest point. ^ For front disc brake shoes, when a set of brake shoes are worn to a thickness of approximately 7.95 mm (5/16 inch), they should be replaced. ^ For rear disc brake shoes, when a set of brake shoes are worn to a thickness of approximately 7.0 mm (9/32 inch), they should be replaced. ^ Typically, if front shoes are worn out, both fronts and rears need to be replaced. Make sure to check rears. Replace both disc brake shoes (inboard and outboard) on each caliper. It is necessary to replace the shoes on the opposite side of the vehicle as well as the shoes failing inspection. If the brake shoe assemblies do not require replacement, be sure to reinstall the brake shoes in the original position they were removed from. INSTALLATION INSTALLATION - FRONT DISC BRAKE SHOES (CONTINENTAL TEVES BRAKES) NOTE: There may be more than 1 lining material released. Make sure proper linings are being installed. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5961 1. Begin on one side of the vehicle or the other. 2. Completely retract the caliper piston back into its bore in the brake caliper (This is required for caliper installation on the brake rotor with new brake shoes installed). 3. If applied, remove the protective paper from the noise suppression gasket on the rear of both the inner and outer brake shoe assemblies. 4. Install the new inboard brake shoe into the caliper piston by firmly pressing its retaining clip into the piston bore. Be sure the inboard brake shoe is positioned squarely against the face of the caliper piston. 5. Lubricate both adapter abutments where the shoes slide with a small amount of Mopar Dielectric grease, or equivalent. 6. Slide the new outboard brake shoe into the caliper adapter with the lining up against the outside of the brake rotor. CAUTION: Use care when installing the caliper assembly onto the caliper adapter, so the caliper guide pin bushings do not get damaged by the adapter bosses. 7. Carefully position the brake caliper over the brake rotor and adapter. 8. Install the caliper guide pin bolts and tighten to a torque of 35 Nm (26 ft. lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts. 9. Install the caps over the caliper guide pin bolts. 10. Install the new caliper hold down spring (antirattle clip) on the outboard side of the caliper. Start the spring into the holes on the caliper, then stretch the clip legs past the abutments on the caliper adapter. 11. Repeat the above procedure on other side of the vehicle. 12. Install the wheel and tire assemblies. Tighten the wheel mounting nuts in proper sequence until all nuts are torqued to half specification, then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 13. Lower vehicle. 14. Pump the brake pedal several times. This will set the shoes to the brake rotor. 15. Check and adjust brake fluid level as necessary. 16. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes. INSTALLATION - FRONT DISC BRAKE SHOES (TRW BRAKES) NOTE: Perform steps Step 1 through Step 5 on each side of the vehicle. 1. Place the brake shoes in the adapter anti-rattle clips. 2. Completely retract the caliper piston back into the bore of the caliper. CAUTION: Use care when installing the caliper onto the disc brake adapter to avoid damaging the boots on the caliper guide pins. 3. Install the disc brake caliper over the brake shoes on the brake caliper adapter. 4. Align the caliper guide pin bolt holes with the guide pins. Install the caliper guide pin bolts and tighten them to a torque of 35 Nm (26 ft. lbs.) (Fig. 13). 5. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Pump the brake pedal several times. This will set the shoes to the brake rotor. 8. Check and adjust the brake fluid level as necessary. 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5962 Brake Pad: Service and Repair Rear REMOVAL - REAR DISC BRAKE SHOES 1. Raise vehicle. 2. Remove rear wheel and tire assemblies from vehicle. 3. Remove the caliper to adapter guide pin bolts (Fig. 14) 4. Remove rear caliper from adapter using the following procedure. First rotate front of caliper up from the adapter. Then pull the rear of the caliper and the outboard brake shoe anti-rattle clip out from under the rear abutment on the adapter (Fig. 15). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5963 5. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose (Fig. 16). 6. If the brake rotor needs to be removed it can be removed by removing the retainer clips and then pulling the rotor straight off the wheel mounting studs. 7. Remove the outboard brake shoe from the caliper. Brake shoe is removed by pushing the shoe toward the piston, disengaging the two metal protrusions on the shoe back, then sliding the brake shoe off the caliper. 8. Remove inboard brake shoe from caliper. Inboard brake shoe is removed by pulling it out of the caliper piston, until the retaining clip is free of the piston (Fig. 17). CLEANING - DISC BRAKE SHOES WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. INSPECTION - DISC BRAKE SHOES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 5964 Visually inspect brake shoes (pads) for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators on the shoes (if equipped) and the brake rotors. If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the disc brake shoes from the calipers. Measure each brake shoe. The combined brake shoe and its lining material thickness should be measured at its thinnest point. ^ For front disc brake shoes, when a set of brake shoes are worn to a thickness of approximately 7.95 mm (5/16 inch), they should be replaced. ^ For rear disc brake shoes, when a set of brake shoes are worn to a thickness of approximately 7.0 mm (9/32 inch), they should be replaced. ^ Typically, if front shoes are worn out, both fronts and rears need to be replaced. Make sure to check rears. Replace both disc brake shoes (inboard and outboard) on each caliper. It is necessary to replace the shoes on the opposite side of the vehicle as well as the shoes failing inspection. If the brake shoe assemblies do not require replacement, be sure to reinstall the brake shoes in the original position they were removed from. INSTALLATION - REAR DISC BRAKE SHOES 1. Completely retract caliper piston back into piston bore of caliper assembly. 2. Lubricate both adapter abutments where the shoes contact with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. 3. If removed, install the brake rotor on the hub, making sure it is squarely seated on the face of the hub. 4. Install the inboard brake shoe into the caliper piston by firmly pressing it into the piston bore using your thumbs. Be sure inboard brake shoe is positioned squarely against the face of the caliper piston. NOTE: The outboard shoes are different left to right. They can be identified by a L or R stamped on the clip. 5. Install the outboard brake shoe on the disc brake caliper. Be sure the outboard shoe is positioned squarely against the outboard fingers of the caliper. CAUTION: Use care when installing the caliper assembly onto the adapter, so the caliper guide pin bushings do not get damaged by the mounting bosses. 6. Carefully lower caliper and brake shoes over rotor and onto adapter, reversing the removal procedure (Fig. 15). CAUTION: When installing the caliper guide pin bolts extreme caution should be taken not to crossthread the guide pin bolts. 7. Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 35 Nm (26 ft. lbs.). 8. Install the wheel and tire assembly. Tighten the wheel mounting nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 9. Lower vehicle. CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal to adequately stop the vehicle. 10. Pump brake pedal several times to set brake shoes to rotors. 11. Check fluid level in reservoir. 12. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest for Brake Rotor/Disc: > 05-002-05 > Jan > 05 > Brakes Vibration/Pulsation Felt in Steering Wheel Brake Rotor/Disc: Customer Interest Brakes - Vibration/Pulsation Felt in Steering Wheel NUMBER: 05-002-05 GROUP: Brakes DATE: January 29, 2005 SUBJECT: Pulsation Or Vibration In The Brake Pedal and/or Steering Wheel OVERVIEW: This bulletin involves replacing the brake rotors instead of resurfacing. MODELS: 2005 RS Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with disc/drum brakes (sales code BRB), built on July 1, 2004 through and including September 30, 2004 (MDH 0701XX through and including 0930XX). DISCUSSION: The vehicle may exhibit pulsation or vibration in the brake pedal and/or steering wheel when the brakes are applied. This condition is most noticeable at speeds greater than 30 MPH. The original equipment rotors on these vehicles cannot be corrected by resurfacing. If the owner describes this condition and if the vehicle is built with a disc/drum system (sales code BRB) between July 1, 2004 through and including September 30, 2004, perform the Repair Procedure. The old rotors are to be returned, in the box, through the normal warranty return process. PARTS REQUIRED: REPAIR PROCEDURE: 1. Raise vehicle on a suitable hoist. 2. Remove the front wheel and tire assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest for Brake Rotor/Disc: > 05-002-05 > Jan > 05 > Brakes Vibration/Pulsation Felt in Steering Wheel > Page 5973 3. Remove the two mounting bolts securing the disc brake caliper adapter with brake caliper to the steering knuckle (Fig. 1). 4. Remove the disc brake caliper and adapter as an assembly from the steering knuckle. Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this (Fig. 1). 5. Remove any retainer clips from the wheel mounting studs. 6. Remove brake rotor from hub by pulling it straight off the wheel mounting studs. NOTE: Step # 7 is to be performed through June 30, 2005. After that date proceed to Step # 8. 7. Place a tag on the rotor with the following information: the last eight characters of the VIN, vehicle mileage, and location on the vehicle (ie. Right Front = RF or Left Front = LF). Place the old rotor in the box that the new rotor was in. 8. Install the new brake rotor, p/n 05019981AA, on the hub and bearing. 9. Install the brake caliper and adapter back over brake rotor aligning the adapter with mounting holes on the steering knuckle (Fig. 1). 10. Install the two adapter mounting bolts securing the adapter to the steering knuckle. Tighten the mounting bolts to 169 N.m (125 ft.lbs.) torque. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest for Brake Rotor/Disc: > 05-002-05 > Jan > 05 > Brakes Vibration/Pulsation Felt in Steering Wheel > Page 5974 11. Install the wheel and tire assembly on the vehicle. Tighten the wheel mounting lug nuts in proper sequence until all nuts are torqued to half specification, then repeat the tightening sequence to the full specified torque of 135 N.m (100 ft.lbs.) (Fig. 2). 12. Repeat Step # 2 through Step # 12 on the opposite side of the vehicle. When both front rotors have been replaced, proceed to Step # 13. 13. Lower vehicle to the ground. 14. Pump the brake pedal several times. This will set the pads to the brake rotor. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 05-002-05 > Jan > 05 > Brakes - Vibration/Pulsation Felt in Steering Wheel Brake Rotor/Disc: All Technical Service Bulletins Brakes - Vibration/Pulsation Felt in Steering Wheel NUMBER: 05-002-05 GROUP: Brakes DATE: January 29, 2005 SUBJECT: Pulsation Or Vibration In The Brake Pedal and/or Steering Wheel OVERVIEW: This bulletin involves replacing the brake rotors instead of resurfacing. MODELS: 2005 RS Town & Country/Caravan NOTE: This bulletin applies to vehicles equipped with disc/drum brakes (sales code BRB), built on July 1, 2004 through and including September 30, 2004 (MDH 0701XX through and including 0930XX). DISCUSSION: The vehicle may exhibit pulsation or vibration in the brake pedal and/or steering wheel when the brakes are applied. This condition is most noticeable at speeds greater than 30 MPH. The original equipment rotors on these vehicles cannot be corrected by resurfacing. If the owner describes this condition and if the vehicle is built with a disc/drum system (sales code BRB) between July 1, 2004 through and including September 30, 2004, perform the Repair Procedure. The old rotors are to be returned, in the box, through the normal warranty return process. PARTS REQUIRED: REPAIR PROCEDURE: 1. Raise vehicle on a suitable hoist. 2. Remove the front wheel and tire assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 05-002-05 > Jan > 05 > Brakes - Vibration/Pulsation Felt in Steering Wheel > Page 5980 3. Remove the two mounting bolts securing the disc brake caliper adapter with brake caliper to the steering knuckle (Fig. 1). 4. Remove the disc brake caliper and adapter as an assembly from the steering knuckle. Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this (Fig. 1). 5. Remove any retainer clips from the wheel mounting studs. 6. Remove brake rotor from hub by pulling it straight off the wheel mounting studs. NOTE: Step # 7 is to be performed through June 30, 2005. After that date proceed to Step # 8. 7. Place a tag on the rotor with the following information: the last eight characters of the VIN, vehicle mileage, and location on the vehicle (ie. Right Front = RF or Left Front = LF). Place the old rotor in the box that the new rotor was in. 8. Install the new brake rotor, p/n 05019981AA, on the hub and bearing. 9. Install the brake caliper and adapter back over brake rotor aligning the adapter with mounting holes on the steering knuckle (Fig. 1). 10. Install the two adapter mounting bolts securing the adapter to the steering knuckle. Tighten the mounting bolts to 169 N.m (125 ft.lbs.) torque. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 05-002-05 > Jan > 05 > Brakes - Vibration/Pulsation Felt in Steering Wheel > Page 5981 11. Install the wheel and tire assembly on the vehicle. Tighten the wheel mounting lug nuts in proper sequence until all nuts are torqued to half specification, then repeat the tightening sequence to the full specified torque of 135 N.m (100 ft.lbs.) (Fig. 2). 12. Repeat Step # 2 through Step # 12 on the opposite side of the vehicle. When both front rotors have been replaced, proceed to Step # 13. 13. Lower vehicle to the ground. 14. Pump the brake pedal several times. This will set the pads to the brake rotor. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > USA Brake Rotor/Disc: Specifications USA BRAKE ROTOR When refacing a rotor, the required TIR (Total Indicator Reading) and thickness variation limits MUST BE MAINTAINED. Extreme care in the operation of rotor turning equipment is required. LIMITS/SPECIFICATIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > USA > Page 5984 Brake Rotor/Disc: Specifications Export BRAKE ROTOR - EXPORT NOTE: Use the following information on all 4 wheel disc brake vehicles that are equipped with BR3 sales code. When refacing a rotor, the required TIR (Total Indicator Reading) and thickness variation limits MUST BE MAINTAINED. Extreme care in the operation of rotor turning equipment is required. LIMITS/SPECIFICATIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5985 Brake Rotor/Disc: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE ROTOR Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. Excessive runout or wobble in a rotor can increase pedal travel due to piston knock-back. This increases guide pin sleeve wear due to the tendency of the caliper to follow the rotor wobble. When diagnosing a brake noise or pulsation, the machined disc braking surface should be checked and inspected. BRAKING SURFACE INSPECTION Light braking surface scoring and wear is acceptable. If heavy scoring or warping is evident, the rotor must be refaced or replaced. Excessive wear and scoring of the rotor can cause improper lining contact on the rotor's braking surface. If the ridges on the rotor are not removed before new brake shoes are installed, improper wear of the shoes will result. If a vehicle has not been driven for a period of time, the rotor's braking surface will rust in the areas not covered by the brake shoes at that time. Once the vehicle is driven, noise and chatter from the disc brakes can result when the brakes are applied. Some discoloration or wear of the rotor surface is normal and does not require resurfacing when linings are replaced. If cracks or burned spots are evident, the rotor must be replaced. ROTOR MINIMUM THICKNESS Measure rotor thickness at the center of the brake shoe contact surface. Replace the rotor if it is worn below minimum thickness or if machining the rotor will cause its thickness to fall below specifications. CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness. Minimum thickness specifications are cast on the rotor's unmachined surface (Fig. 82). Limits can also be found in the specification table. ROTOR THICKNESS VARIATION Thickness variation in a rotor's braking surface can result in pedal pulsation, chatter and surge. This can be caused by excessive runout in the rotor or the hub. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5986 Rotor thickness variation measurements should be made in conjunction with measuring runout. Measure thickness of the brake rotor at 12 equal points around the rotor braking surface with a micrometer at a radius approximately 25 mm (1 inch) from edge of rotor (Fig. 83). If thickness measurements vary beyond the specification listed in the specification table, the rotor should be refaced or replaced. ROTOR RUNOUT On-vehicle rotor runout is the combination of the individual runout of the hub face and the runout of the rotor. (The hub and rotor runouts are separable). To measure rotor runout on the vehicle, first remove the tire and wheel assembly. Reinstall the wheel mounting nuts on the studs, tightening the rotor to the hub. Mount the Dial Indicator, Special Tool C-3339, with Mounting Adaptor, Special Tool SP1910 on steering arm. The dial indicator plunger should contact braking surface of rotor approximately ten millimeters from edge of rotor (Fig. 84). Check lateral runout on both sides of the rotor, marking the low and high spots on both. Runout limits can be found in the specification table. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5987 If runout is in excess of the specification, check the lateral runout of the hub face. Before removing the rotor from the hub, place a chalk mark across both the rotor and the one wheel stud closest to where the high runout measurement was taken. This way, the original mounting spot of the rotor on the hub is indexed (Fig. 85). Remove the rotor from the hub. NOTE: Clean the hub face surface before checking runout. This provides a clean surface to get an accurate indicator reading. Mount Dial Indicator, Special Tool C-3339, and Mounting Adaptor, Special Tool SP-1910, to the steering knuckle. Position the indicator stem so it contacts the hub face near the outer diameter. Care must be taken to position stem outside of the stud circle, but inside of the chamfer on the hub rim (Fig. 86). Hub runout should not exceed 0.03 mm (0.0012 inch). If runout exceeds this specification, the hub must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5988 If the hub runout does not exceed this specification, install the rotor back on the hub, aligning the chalk marks on the rotor with a wheel mounting stud, two studs apart from the original stud (Fig. 87). Tighten nuts in the proper sequence and torque to specifications. Recheck brake rotor runout to see if the runout is now within specifications. If runout is not within specifications, reface or replace the brake rotor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures Brake Rotor/Disc: Procedures Brake Rotor Machining STANDARD PROCEDURE - BRAKE ROTOR MACHINING NOTE: Refacing the rotor is not required each time the brake pads are replaced, only when the need is foreseen. Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. If the rotor surface is deeply scored or warped, or there is a complaint of brake roughness or brake pedal pulsation, the rotor should be refaced using a hub-mounted on-car brake lathe (Fig. 88), or replaced. The use of a hub-mounted on-car brake lathe is highly recommended to eliminate the possibility of excessive runout. It trues the brake rotor to the vehicle's hub and bearing. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5991 NOTE: All rotors have markings for minimum allowable thickness cast on an un-machined surface of the rotor (Fig. 89) (Fig. 90). Minimum thickness specifications can also be found in the specification table. Minimum allowable thickness is the minimum thickness which the brake rotor machined surface may be cut to. CAUTION: Do not machine the rotor if it will cause the rotor to fall below minimum thickness. Before installation, verify the brake rotor face and the hub adapters are free of any chips, rust, or contamination. When mounting and using the brake lathe, strict attention to the brake lathe manufacturer's operating instructions is required. Machine both sides of the brake rotor at the same time. Cutting both sides at the same time minimizes the possibility of a tapered or uneven cut. When refacing a rotor, the required TIR (Total Indicator Reading) and thickness variation limits MUST BE MAINTAINED. Extreme care in the operation of rotor turning equipment is required. Specifications for brake rotor machining can be found in the specification table. Removal and Installation REMOVAL - FRONT BRAKE ROTOR 1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the front wheel and tire assembly. 3. Remove the two mounting bolts securing the disc brake caliper adapter with brake caliper to the steering knuckle (Fig. 91). 4. Remove the disc brake caliper and adapter as an assembly from the steering knuckle (Fig. 91). Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this. 5. Remove any retainer clips from the wheel mounting studs. 6. Remove brake rotor from hub by pulling it straight off wheel mounting studs (Fig. 91). INSTALLATION - FRONT BRAKE ROTOR 1. Install the brake rotor back on the hub and bearing (Fig. 91). 2. Install brake caliper and adapter back over brake rotor aligning adapter with mounting holes on steering knuckle (Fig. 91). 3. Install the two adapter mounting bolts securing the adapter to the steering knuckle. Tighten the mounting bolts to 169 Nm (125 ft. lbs.) torque. 4. Install wheel and tire assembly on vehicle. Tighten the wheel mounting lug nuts in proper sequence until all nuts are torqued to half specification, then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 5. Lower vehicle to the ground. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5992 Brake Rotor/Disc: Removal and Replacement Front Brake Rotor REMOVAL - FRONT BRAKE ROTOR 1. Raise vehicle on jackstands or centered on a frame contact type hoist. See Hoisting in Lubrication and Maintenance. 2. Remove the front wheel and tire assembly. 3. Remove the two mounting bolts securing the disc brake caliper adapter with brake caliper to the steering knuckle (Figure 1). Figure 1 Front Brake Mounting 4. Remove the disc brake caliper and adapter as an assembly from the steering knuckle (Figure 1). Hang the assembly out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this. 5. Remove any retainer clips from the wheel mounting studs. 6. Remove brake rotor from hub by pulling it straight off wheel mounting studs (Figure 1). Rear Brake Rotor REMOVAL - REAR BRAKE ROTOR NOTE: Handling of the rotor and caliper, must be done in such a way as to avoid damage to the rotor and scratching or nicking of lining on the brake shoes. 1. Raise the vehicle. 2. Remove rear wheel and tire assembly from vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5993 Figure 1 3. Remove the disc brake caliper to adapter guide pin bolts as shown in figure 1. Figure 2 4. Remove rear caliper from adapter using the following procedure. First rotate front of caliper up from the adapter. Then pull the rear of the caliper and the outboard brake shoe anti-rattle clip out from under the rear abutment on the adapter as shown in figure 2. Figure 3 5. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose as shown in figure 3. 6. Remove the retainer clips from the wheel mounting studs, then pull the rotor straight off the studs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5994 Front Brake Rotor INSTALLATION - FRONT BRAKE ROTOR 1. Install the brake rotor back on the hub and bearing (Figure 1). 2. Install brake caliper and adapter back over brake rotor aligning adapter with mounting holes on steering knuckle (Figure 1). 3. Install the two adapter mounting bolts securing the adapter to the steering knuckle. Tighten the mounting bolts to 169 Nm (125 ft. lbs.) torque. 4. Install wheel and tire assembly on vehicle. Tighten the wheel mounting lug nuts in proper sequence until all nuts are torqued to half specification, then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 5. Lower vehicle to the ground. Figure 1 Front Brake Mounting Rear Brake Rotor INSTALLATION 1. Completely retract caliper piston back into piston bore of the caliper. 2. Install the brake rotor on the hub, making sure it is squarely seated on the face of the hub. CAUTION: Use care when installing the caliper assembly onto the adapter, so the caliper guide pin bushings do not get damaged by the mounting bosses. 3. Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse procedure for removal. CAUTION: When installing guide pin bolts extreme caution should be taken not to cross-thread the caliper guide pin bolts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5995 4. Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 35 Nm (26 ft.lbs). 5. Install the wheel and tire assembly. 6. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft.lbs). 7. Lower the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion Technical Service Bulletin # 05-001-06A Date: 060923 Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion NUMBER: 05-001-06 REV A GROUP: Brakes DATE: September 23, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-001-06, DATED MARCH 9, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED PART NUMBER. SUBJECT: Snow/Water Ingestion Into Rear Brake Drum OVERVIEW: This bulletin involves installing a revised rear drum brake support (backing) plate and possible replacement of the rear brake shoes and drums. MODELS: 2001 - 2006 (RS) Town & Country/Voyager/Caravan 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (CS) Chrysler Voyager (International Markets) NOTE: This bulletin applies to vehicles equipped with sales codes BRA, BRB, or BRV (front disc/rear drum brakes) built on or before March 7, 2006 (MDH 0307XX). SYMPTOM/CONDITION: While driving through deep or blowing snow/water, the snow/water may enter the rear brake drums causing rust to develop on the rear brake drum and shoe friction surfaces. This condition can lead to temporary freezing of the rear brake linings to the drums. This symptom is experienced after the vehicle has been parked in below freezing temperatures long enough for the snow/water to freeze inside of the rear brake drums. When the parking brake has been applied the symptom is more likely to occur. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair Procedure. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6001 EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Raise the vehicle on a suitable hoist. 2. Remove both rear wheel and tire assemblies. 3. Remove both brake drums. It may be necessary to adjust the rear shoes to aid in removing the drum. 4. Create slack in the rear park brake cables. With the park brake pedal in the released position pull down and rearward on the core of the front park brake cable then install a pair of locking pliers on the core of the front park brake cable just rearward of the rear body outrigger bracket (Fig. 1). 5. Lower the vehicle so that it is low enough to access the brake pedal. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6002 6. Use a brake pedal depressor to move and hold the brake pedal to a position past the first inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tube is removed from the wheel cylinder. 7. Raise the vehicle. 8. Remove the adjustment lever spring from the adjustment lever and leading brake shoe, (Fig. 2) 9. Remove the adjustment lever from the leading brake shoe. 10. Remove the brake shoe lower return springs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6003 11. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly (Fig. 3) 12. Remove the brake shoe to brake shoe upper return spring. 13. Remove the trailing brake shoe assembly hold down spring and pin. 14. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating lever and the park brake actuating strut, (Fig. 4) 15. Remove the automatic adjuster assembly from the leading shoe. 16. Remove the leading brake shoe assembly hold down spring and pin. Remove the leading brake shoe assembly. 17. Replace the rear brake shoes using p/n 05183395AA. Remove the park brake actuator plate from the leading brake shoe and install it to the replacement brake shoe. 18. Disconnect the park brake cable from the park brake actuation lever. 19. Remove the rear wheel speed sensor if so equipped. The hub/bearing assembly cannot be removed unless the speed sensor is removed first. CAUTION: WHEN WORKING IN THE AREA OF THE REAR HUB/BEARING ASSEMBLY AND WHEN REMOVING IT FROM THE REAR AXLE, CARE MUST BE USED SO THE TEETH OF THE TONE WHEEL ARE NOT DAMAGED. DAMAGE TO THE TONE WHEEL TEETH WILL RESULT IN FALSE ABS CYCLING AND CORROSION OF THE TONE WHEEL. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6004 20. Using a suitable tool such as a 14 mm box end wrench compress the flared legs on the park brake cable retainer. Then pull the park brake cable out of the support plate (Fig. 5) 21. Disconnect the brake tube from the wheel cylinder. 22. Remove the two bolts attaching the wheel cylinder to the brake support plate and separate the wheel cylinder from the vehicle. 23. Remove the 4 bolts attaching the hub/bearing assembly to the flange of the rear axle. CAUTION: CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE MAKING IT DIFFICULT TO REMOVE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND DO NOT HIT/POUND THE HUB/BEARING. POUNDING ON THE HUB/BEARING WILL CAUSE DAMAGE TO THE BEARING THAT RESULTS IN NOISE OR BEARING FAILURE. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6005 24. If the hub/bearing cannot be removed by hand, for GS/NS vehicles use remover Special Tool 8214, (Fig. 6), for RS skip to step 25. a. Place Special Tool 8214-1 over the tone wheel and against the cast flange of the hub/bearing. Put a dab of grease in the bolt pilot hole on the back of the tool. b. Insert Special Tool 8214-2 into the hole in the bottom of the end casting on the axle. If Special Tool 8214-2 will not fit into the hole in the end casting, file or grind the flashing from the hole until the tool fits properly. Special Tool 8214-2 must be against and supported by the axle plate when pressing the bearing out of the axle. c. Align bolt in Special Tool 8214-2 with the pilot hole in Special Tool 8214-1. Tighten the bolt against Special Tool 8214-1. d. Press the hub/bearing out of the axle by continuing to tighten the bolt in Special Tool 8214-2 against Special Tool 8214-1. Proceed to step 26. 25. If the hub/bearing cannot be removed by hand, for RS vehicles use remover Special Tool 8458 (Fig. 7) a. Thread threaded guide pins into hub and bearing mounting holes. b. Remove the two outboard spring plate bolts. c. Using the spring plate bolts, install the screw mount, special tool 8458-2. d. Place push plate, special tool 8458-1, on the ends of the threaded guide pins. e. Place a dab of grease in the dimple of the push plate. f. Tighten the forcing screw, special tool 8458-3, against the dimple in the push plate and press the hub and bearing assembly out of the axle by continuing to tighten the screw. g. Remove the tool. h. Reinstall the two outboard spring plate bolts and torque to 102 Nm (75 ft. lbs.). 26. Remove the hub/bearing from the rear axle and brake support plate. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6006 27. Remove the brake support plate from the vehicle. Remove the rubber plug(s) in the manual adjuster and lining inspection slot(s) as equipped, for use in the replacement support plate. Discard the support plate. 28. Insert the 4 hub/bearing mounting bolts into the holes in the flange of the rear axle. 29. Install the revised brake support plate, p/n 05016612/3AA on the 4 bolts inserted in the flange of the rear axle, make sure the park brake cable hole in the support plate faces toward the front of the vehicle. 30. Align the hub/bearing with the 4 mounting bolts and finger tighten the bolts into the hub/bearing. Tighten the 4 bolts in a crisscross pattern until the hub/bearing is fully seated into the flange of the rear axle. 31. Torque the 4 hub/bearing mounting bolts to 129 Nm (95 ft. lbs.). NOTE: FOR NS-VEHICLES BUILT PRIOR TO SEPT. 27, 1996 (MDH 0927XX) AT THE ST. LOUIS ASSEMBLY PLANT (LETTER "B" IN THE 11TH POSITION OF THE VIN) AND BUILT PRIOR TO OCT. 28 1996 (MDH 1028XX) AT THE WINDSOR ASSEMBLY PLANT (LETTER "R" IN THE 11TH POSITION OF THE VIN), THAT HAVE THEIR ORIGINAL REAR BRAKE COMPONENTS, IF THE REAR BRAKE SHOES REQUIRE REPLACEMENT, WHEEL CYLINDERS (13/16 IN.), P/N 04883830AA, MUST ALSO BE INSTALLED. IF TSB 05-06-96, 05-06-96 REV.A OR 05-01-97 HAVE BEEN PERFORMED ON THE VEHICLE, WHEEL CYLINDER REPLACEMENT IS NOT REQUIRED. 32. Apply a sealant such as Mopar RTV, p/n 05010884AA, or equivalent around the wheel cylinder opening in the revised brake support plate. 33. Attach the wheel cylinder to the revised brake support plate before the sealant cures, torque the 2 mounting bolts to 8 Nm (75 in. lbs.). 34. Install the brake tube into the wheel cylinder and torque the tube nut to 16 Nm (142 in. lbs.) 35. Install the rear wheel speed sensor if so equipped. CS/NS vehicles: torque the attaching bolt to 12 Nm (105 in. lbs.). 36. For GS/NS without ABS and all RS vehicles fill any existing gap between the bearing flange and the ABS sensor hole in the support plate with Mopar RTV sealant, p/n 05010884AA. 37. Install the rear park brake cable into its mounting hole in the brake support plate. 38. Install the park brake cable to the park brake actuator lever. 39. Lubricate the eight brake shoe contact areas on the support plate using the required special Mopar Brake Lubricant p/n 04796269. 40. Install the leading brake shoe, hold down, pin and spring onto the brake support plate. 41. Install the park brake actuator strut on the leading brake shoe. Then install the park brake actuator lever on the strut. 42. Install the automatic adjuster assembly on the leading brake shoe. Then install the trailing brake shoe on the park brake actuator lever and park brake actuator strut. Position the trailing brake shoe on the brake support plate. 43. Install the trailing brake shoe hold down, pin and spring onto the brake support plate. 44. Install the upper brake shoe to brake shoe return spring. CAUTION: WHEN INSTALLING THE TENSION CLIP ON THE AUTOMATIC ADJUSTER, THE CLIP MUST BE LOCATED ON THE THREADED AREA OF THE ADJUSTER ASSEMBLY. IF IT IS LOCATED ON THE NON-THREADED AREA OF THE ADJUSTER, THE FUNCTION OF THE AUTOMATIC ADJUSTER WILL BE AFFECTED. 45. Install the tension clip attaching the upper return spring to the automatic adjuster. 46. Install the lower brake shoe to brake shoe return springs. 47. Install the automatic adjuster lever on the leading brake shoe. 48. Install the actuating spring on the automatic adjuster lever and the leading brake shoe. 49. Verify the automatic adjuster lever has positive contact with the star wheel on the automatic adjuster assembly. 50. Repeat steps 8 through 48 for the other side rear brake assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6007 51. When all components of both rear brake assemblies are correctly and fully installed, remove the locking pliers from the front park brake cable. 52. Adjust the rear brakes so they do not interfere with installing the brake drums. 53. Install both rear brake drums. Install the original drums as removed unless their condition justifies turning or replacement. 54. Install both rear tire/wheel assemblies. Torque the lug nuts using a crisscross pattern to 135 Nm (100 ft. lbs.). 55. Insert a thin flat blade screwdriver through the adjusting hole in the support plate until it is against the star wheel of the adjuster assembly. Move the handle of the screwdriver upward rotating the star wheel until slight drag is felt when the tire/wheel assembly is turned. 56. Insert a second screwdriver or piece of stiff wire into the brake adjusting hole and push against the adjuster lever to disengage it from the star wheel. Care should be taken not bend the adjusting lever or distort the lever spring. 57. While the adjuster lever is disengaged from the star wheel turn the star wheel just enough to eliminate the drag felt when the tire/wheel assembly is turned. 58. Install the adjusting/inspection hole rubber plug(s) saved in step 26 59. Repeat steps 55 through 58 for the other side rear brake. 60. Perform the base brake bleeding procedure described in the appropriate service manual. 61. Lower the vehicle to the floor. 62. Push the park brake pedal down fully and release to adjust the park brake cables. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Page 6008 Backing Plate: Service and Repair SUPPORT PLATE - DRUM BRAKE REMOVAL 1. Using a brake pedal depressor, move and secure brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of master cylinder when brake tube is remove from wheel cylinder. 2. Raise vehicle. 3. Remove wheel and tire assembly. 4. Disconnect brake tube from rear of wheel cylinder. Cap open ends 5. Remove brake drum. 6. Remove brake shoes from brake support plate. 7. Remove the 2 bolts attaching the wheel cylinder to the brake support plate. 8. Remove the wheel cylinder from the brake support plate. 9. Disconnect the park brake cable from the park brake actuation lever. 10. Using a suitable tool such as a 14 mm box wrench (Fig. 92) or an aircraft type hose clamp, compress the flared legs on park brake cable retainer. Then pull the park brake cable out of brake support plate. 11. Remove the rear hub and bearing. 12. Remove the rear brake support plate from the rear axle. INSTALLATION 1. Install the 4 hub and bearing to axle mounting bolts into the mounting holes in the flange of the rear axle. 2. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle (Fig. 93). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Technical Service Bulletins > Page 6009 3. Install the rear hub and bearing (and connect wheel speed sensor where applicable) stopping short of installing the brake drum. 4. Install the rear park brake cable into its mounting hole in the rear brake support plate. 5. Install the park brake cable on the park brake actuation lever. 6. Apply sealant such as Mopar Gasket-In-A-Tube or equivalent around the wheel cylinder opening in the brake support plate. 7. Install wheel cylinder onto brake support. Install and tighten the wheel cylinder to brake support plate attaching bolts to 8 Nm (75 inch lbs.) torque. 8. Install brake tube into wheel cylinder. Tighten tube nut to a torque of 17 Nm (145 inch lbs.) torque. 9. Install the rear brake shoes on the brake support plate. 10. Install brake drum. 11. Install the wheel and tire assembly. Tighten the wheel mounting nuts in proper sequence until all nuts are torqued to half specification, then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 12. Adjust drum brake shoes. 13. Remove brake pedal depressor tool. 14. Bleed the brake system as necessary. 15. Lower the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion Technical Service Bulletin # 05-001-06A Date: 060923 Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion NUMBER: 05-001-06 REV A GROUP: Brakes DATE: September 23, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-001-06, DATED MARCH 9, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED PART NUMBER. SUBJECT: Snow/Water Ingestion Into Rear Brake Drum OVERVIEW: This bulletin involves installing a revised rear drum brake support (backing) plate and possible replacement of the rear brake shoes and drums. MODELS: 2001 - 2006 (RS) Town & Country/Voyager/Caravan 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (CS) Chrysler Voyager (International Markets) NOTE: This bulletin applies to vehicles equipped with sales codes BRA, BRB, or BRV (front disc/rear drum brakes) built on or before March 7, 2006 (MDH 0307XX). SYMPTOM/CONDITION: While driving through deep or blowing snow/water, the snow/water may enter the rear brake drums causing rust to develop on the rear brake drum and shoe friction surfaces. This condition can lead to temporary freezing of the rear brake linings to the drums. This symptom is experienced after the vehicle has been parked in below freezing temperatures long enough for the snow/water to freeze inside of the rear brake drums. When the parking brake has been applied the symptom is more likely to occur. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair Procedure. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6014 EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Raise the vehicle on a suitable hoist. 2. Remove both rear wheel and tire assemblies. 3. Remove both brake drums. It may be necessary to adjust the rear shoes to aid in removing the drum. 4. Create slack in the rear park brake cables. With the park brake pedal in the released position pull down and rearward on the core of the front park brake cable then install a pair of locking pliers on the core of the front park brake cable just rearward of the rear body outrigger bracket (Fig. 1). 5. Lower the vehicle so that it is low enough to access the brake pedal. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6015 6. Use a brake pedal depressor to move and hold the brake pedal to a position past the first inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tube is removed from the wheel cylinder. 7. Raise the vehicle. 8. Remove the adjustment lever spring from the adjustment lever and leading brake shoe, (Fig. 2) 9. Remove the adjustment lever from the leading brake shoe. 10. Remove the brake shoe lower return springs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6016 11. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly (Fig. 3) 12. Remove the brake shoe to brake shoe upper return spring. 13. Remove the trailing brake shoe assembly hold down spring and pin. 14. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating lever and the park brake actuating strut, (Fig. 4) 15. Remove the automatic adjuster assembly from the leading shoe. 16. Remove the leading brake shoe assembly hold down spring and pin. Remove the leading brake shoe assembly. 17. Replace the rear brake shoes using p/n 05183395AA. Remove the park brake actuator plate from the leading brake shoe and install it to the replacement brake shoe. 18. Disconnect the park brake cable from the park brake actuation lever. 19. Remove the rear wheel speed sensor if so equipped. The hub/bearing assembly cannot be removed unless the speed sensor is removed first. CAUTION: WHEN WORKING IN THE AREA OF THE REAR HUB/BEARING ASSEMBLY AND WHEN REMOVING IT FROM THE REAR AXLE, CARE MUST BE USED SO THE TEETH OF THE TONE WHEEL ARE NOT DAMAGED. DAMAGE TO THE TONE WHEEL TEETH WILL RESULT IN FALSE ABS CYCLING AND CORROSION OF THE TONE WHEEL. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6017 20. Using a suitable tool such as a 14 mm box end wrench compress the flared legs on the park brake cable retainer. Then pull the park brake cable out of the support plate (Fig. 5) 21. Disconnect the brake tube from the wheel cylinder. 22. Remove the two bolts attaching the wheel cylinder to the brake support plate and separate the wheel cylinder from the vehicle. 23. Remove the 4 bolts attaching the hub/bearing assembly to the flange of the rear axle. CAUTION: CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE MAKING IT DIFFICULT TO REMOVE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND DO NOT HIT/POUND THE HUB/BEARING. POUNDING ON THE HUB/BEARING WILL CAUSE DAMAGE TO THE BEARING THAT RESULTS IN NOISE OR BEARING FAILURE. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6018 24. If the hub/bearing cannot be removed by hand, for GS/NS vehicles use remover Special Tool 8214, (Fig. 6), for RS skip to step 25. a. Place Special Tool 8214-1 over the tone wheel and against the cast flange of the hub/bearing. Put a dab of grease in the bolt pilot hole on the back of the tool. b. Insert Special Tool 8214-2 into the hole in the bottom of the end casting on the axle. If Special Tool 8214-2 will not fit into the hole in the end casting, file or grind the flashing from the hole until the tool fits properly. Special Tool 8214-2 must be against and supported by the axle plate when pressing the bearing out of the axle. c. Align bolt in Special Tool 8214-2 with the pilot hole in Special Tool 8214-1. Tighten the bolt against Special Tool 8214-1. d. Press the hub/bearing out of the axle by continuing to tighten the bolt in Special Tool 8214-2 against Special Tool 8214-1. Proceed to step 26. 25. If the hub/bearing cannot be removed by hand, for RS vehicles use remover Special Tool 8458 (Fig. 7) a. Thread threaded guide pins into hub and bearing mounting holes. b. Remove the two outboard spring plate bolts. c. Using the spring plate bolts, install the screw mount, special tool 8458-2. d. Place push plate, special tool 8458-1, on the ends of the threaded guide pins. e. Place a dab of grease in the dimple of the push plate. f. Tighten the forcing screw, special tool 8458-3, against the dimple in the push plate and press the hub and bearing assembly out of the axle by continuing to tighten the screw. g. Remove the tool. h. Reinstall the two outboard spring plate bolts and torque to 102 Nm (75 ft. lbs.). 26. Remove the hub/bearing from the rear axle and brake support plate. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6019 27. Remove the brake support plate from the vehicle. Remove the rubber plug(s) in the manual adjuster and lining inspection slot(s) as equipped, for use in the replacement support plate. Discard the support plate. 28. Insert the 4 hub/bearing mounting bolts into the holes in the flange of the rear axle. 29. Install the revised brake support plate, p/n 05016612/3AA on the 4 bolts inserted in the flange of the rear axle, make sure the park brake cable hole in the support plate faces toward the front of the vehicle. 30. Align the hub/bearing with the 4 mounting bolts and finger tighten the bolts into the hub/bearing. Tighten the 4 bolts in a crisscross pattern until the hub/bearing is fully seated into the flange of the rear axle. 31. Torque the 4 hub/bearing mounting bolts to 129 Nm (95 ft. lbs.). NOTE: FOR NS-VEHICLES BUILT PRIOR TO SEPT. 27, 1996 (MDH 0927XX) AT THE ST. LOUIS ASSEMBLY PLANT (LETTER "B" IN THE 11TH POSITION OF THE VIN) AND BUILT PRIOR TO OCT. 28 1996 (MDH 1028XX) AT THE WINDSOR ASSEMBLY PLANT (LETTER "R" IN THE 11TH POSITION OF THE VIN), THAT HAVE THEIR ORIGINAL REAR BRAKE COMPONENTS, IF THE REAR BRAKE SHOES REQUIRE REPLACEMENT, WHEEL CYLINDERS (13/16 IN.), P/N 04883830AA, MUST ALSO BE INSTALLED. IF TSB 05-06-96, 05-06-96 REV.A OR 05-01-97 HAVE BEEN PERFORMED ON THE VEHICLE, WHEEL CYLINDER REPLACEMENT IS NOT REQUIRED. 32. Apply a sealant such as Mopar RTV, p/n 05010884AA, or equivalent around the wheel cylinder opening in the revised brake support plate. 33. Attach the wheel cylinder to the revised brake support plate before the sealant cures, torque the 2 mounting bolts to 8 Nm (75 in. lbs.). 34. Install the brake tube into the wheel cylinder and torque the tube nut to 16 Nm (142 in. lbs.) 35. Install the rear wheel speed sensor if so equipped. CS/NS vehicles: torque the attaching bolt to 12 Nm (105 in. lbs.). 36. For GS/NS without ABS and all RS vehicles fill any existing gap between the bearing flange and the ABS sensor hole in the support plate with Mopar RTV sealant, p/n 05010884AA. 37. Install the rear park brake cable into its mounting hole in the brake support plate. 38. Install the park brake cable to the park brake actuator lever. 39. Lubricate the eight brake shoe contact areas on the support plate using the required special Mopar Brake Lubricant p/n 04796269. 40. Install the leading brake shoe, hold down, pin and spring onto the brake support plate. 41. Install the park brake actuator strut on the leading brake shoe. Then install the park brake actuator lever on the strut. 42. Install the automatic adjuster assembly on the leading brake shoe. Then install the trailing brake shoe on the park brake actuator lever and park brake actuator strut. Position the trailing brake shoe on the brake support plate. 43. Install the trailing brake shoe hold down, pin and spring onto the brake support plate. 44. Install the upper brake shoe to brake shoe return spring. CAUTION: WHEN INSTALLING THE TENSION CLIP ON THE AUTOMATIC ADJUSTER, THE CLIP MUST BE LOCATED ON THE THREADED AREA OF THE ADJUSTER ASSEMBLY. IF IT IS LOCATED ON THE NON-THREADED AREA OF THE ADJUSTER, THE FUNCTION OF THE AUTOMATIC ADJUSTER WILL BE AFFECTED. 45. Install the tension clip attaching the upper return spring to the automatic adjuster. 46. Install the lower brake shoe to brake shoe return springs. 47. Install the automatic adjuster lever on the leading brake shoe. 48. Install the actuating spring on the automatic adjuster lever and the leading brake shoe. 49. Verify the automatic adjuster lever has positive contact with the star wheel on the automatic adjuster assembly. 50. Repeat steps 8 through 48 for the other side rear brake assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6020 51. When all components of both rear brake assemblies are correctly and fully installed, remove the locking pliers from the front park brake cable. 52. Adjust the rear brakes so they do not interfere with installing the brake drums. 53. Install both rear brake drums. Install the original drums as removed unless their condition justifies turning or replacement. 54. Install both rear tire/wheel assemblies. Torque the lug nuts using a crisscross pattern to 135 Nm (100 ft. lbs.). 55. Insert a thin flat blade screwdriver through the adjusting hole in the support plate until it is against the star wheel of the adjuster assembly. Move the handle of the screwdriver upward rotating the star wheel until slight drag is felt when the tire/wheel assembly is turned. 56. Insert a second screwdriver or piece of stiff wire into the brake adjusting hole and push against the adjuster lever to disengage it from the star wheel. Care should be taken not bend the adjusting lever or distort the lever spring. 57. While the adjuster lever is disengaged from the star wheel turn the star wheel just enough to eliminate the drag felt when the tire/wheel assembly is turned. 58. Install the adjusting/inspection hole rubber plug(s) saved in step 26 59. Repeat steps 55 through 58 for the other side rear brake. 60. Perform the base brake bleeding procedure described in the appropriate service manual. 61. Lower the vehicle to the floor. 62. Push the park brake pedal down fully and release to adjust the park brake cables. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Page 6021 Brake Drum: Service and Repair DRUM REMOVAL 1. Raise the vehicle. 2. Remove the tire and wheel assembly from the vehicle 3. Remove the rear brake shoe adjusting hole cover plug. 4. Insert a thin screwdriver into brake adjusting hole and hold adjusting lever away from notches of adjusting screw star wheel. 5. Insert another thin screwdriver into brake adjusting hole and engage notches of brake adjusting screw star wheel. Release brake adjustment by prying upward with adjusting tool. 6. Remove rear brake drum from rear hub/bearing assembly. NOTE: It may be necessary to insert M8 X 1.25 MM bolts into the two removal holes on the drum to force the drum off the hub. INSTALLATION 1. Adjust brake shoe assemblies so as not to interfere with brake drum installation. 2. Install the rear brake drums on the hubs. 3. Adjust drum brake shoes as necessary. 4. Install wheel and tire assembly. 5. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 6. Lower the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion Technical Service Bulletin # 05-001-06A Date: 060923 Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion NUMBER: 05-001-06 REV A GROUP: Brakes DATE: September 23, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-001-06, DATED MARCH 9, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED PART NUMBER. SUBJECT: Snow/Water Ingestion Into Rear Brake Drum OVERVIEW: This bulletin involves installing a revised rear drum brake support (backing) plate and possible replacement of the rear brake shoes and drums. MODELS: 2001 - 2006 (RS) Town & Country/Voyager/Caravan 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (CS) Chrysler Voyager (International Markets) NOTE: This bulletin applies to vehicles equipped with sales codes BRA, BRB, or BRV (front disc/rear drum brakes) built on or before March 7, 2006 (MDH 0307XX). SYMPTOM/CONDITION: While driving through deep or blowing snow/water, the snow/water may enter the rear brake drums causing rust to develop on the rear brake drum and shoe friction surfaces. This condition can lead to temporary freezing of the rear brake linings to the drums. This symptom is experienced after the vehicle has been parked in below freezing temperatures long enough for the snow/water to freeze inside of the rear brake drums. When the parking brake has been applied the symptom is more likely to occur. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair Procedure. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6026 EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Raise the vehicle on a suitable hoist. 2. Remove both rear wheel and tire assemblies. 3. Remove both brake drums. It may be necessary to adjust the rear shoes to aid in removing the drum. 4. Create slack in the rear park brake cables. With the park brake pedal in the released position pull down and rearward on the core of the front park brake cable then install a pair of locking pliers on the core of the front park brake cable just rearward of the rear body outrigger bracket (Fig. 1). 5. Lower the vehicle so that it is low enough to access the brake pedal. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6027 6. Use a brake pedal depressor to move and hold the brake pedal to a position past the first inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tube is removed from the wheel cylinder. 7. Raise the vehicle. 8. Remove the adjustment lever spring from the adjustment lever and leading brake shoe, (Fig. 2) 9. Remove the adjustment lever from the leading brake shoe. 10. Remove the brake shoe lower return springs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6028 11. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly (Fig. 3) 12. Remove the brake shoe to brake shoe upper return spring. 13. Remove the trailing brake shoe assembly hold down spring and pin. 14. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating lever and the park brake actuating strut, (Fig. 4) 15. Remove the automatic adjuster assembly from the leading shoe. 16. Remove the leading brake shoe assembly hold down spring and pin. Remove the leading brake shoe assembly. 17. Replace the rear brake shoes using p/n 05183395AA. Remove the park brake actuator plate from the leading brake shoe and install it to the replacement brake shoe. 18. Disconnect the park brake cable from the park brake actuation lever. 19. Remove the rear wheel speed sensor if so equipped. The hub/bearing assembly cannot be removed unless the speed sensor is removed first. CAUTION: WHEN WORKING IN THE AREA OF THE REAR HUB/BEARING ASSEMBLY AND WHEN REMOVING IT FROM THE REAR AXLE, CARE MUST BE USED SO THE TEETH OF THE TONE WHEEL ARE NOT DAMAGED. DAMAGE TO THE TONE WHEEL TEETH WILL RESULT IN FALSE ABS CYCLING AND CORROSION OF THE TONE WHEEL. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6029 20. Using a suitable tool such as a 14 mm box end wrench compress the flared legs on the park brake cable retainer. Then pull the park brake cable out of the support plate (Fig. 5) 21. Disconnect the brake tube from the wheel cylinder. 22. Remove the two bolts attaching the wheel cylinder to the brake support plate and separate the wheel cylinder from the vehicle. 23. Remove the 4 bolts attaching the hub/bearing assembly to the flange of the rear axle. CAUTION: CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE MAKING IT DIFFICULT TO REMOVE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND DO NOT HIT/POUND THE HUB/BEARING. POUNDING ON THE HUB/BEARING WILL CAUSE DAMAGE TO THE BEARING THAT RESULTS IN NOISE OR BEARING FAILURE. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6030 24. If the hub/bearing cannot be removed by hand, for GS/NS vehicles use remover Special Tool 8214, (Fig. 6), for RS skip to step 25. a. Place Special Tool 8214-1 over the tone wheel and against the cast flange of the hub/bearing. Put a dab of grease in the bolt pilot hole on the back of the tool. b. Insert Special Tool 8214-2 into the hole in the bottom of the end casting on the axle. If Special Tool 8214-2 will not fit into the hole in the end casting, file or grind the flashing from the hole until the tool fits properly. Special Tool 8214-2 must be against and supported by the axle plate when pressing the bearing out of the axle. c. Align bolt in Special Tool 8214-2 with the pilot hole in Special Tool 8214-1. Tighten the bolt against Special Tool 8214-1. d. Press the hub/bearing out of the axle by continuing to tighten the bolt in Special Tool 8214-2 against Special Tool 8214-1. Proceed to step 26. 25. If the hub/bearing cannot be removed by hand, for RS vehicles use remover Special Tool 8458 (Fig. 7) a. Thread threaded guide pins into hub and bearing mounting holes. b. Remove the two outboard spring plate bolts. c. Using the spring plate bolts, install the screw mount, special tool 8458-2. d. Place push plate, special tool 8458-1, on the ends of the threaded guide pins. e. Place a dab of grease in the dimple of the push plate. f. Tighten the forcing screw, special tool 8458-3, against the dimple in the push plate and press the hub and bearing assembly out of the axle by continuing to tighten the screw. g. Remove the tool. h. Reinstall the two outboard spring plate bolts and torque to 102 Nm (75 ft. lbs.). 26. Remove the hub/bearing from the rear axle and brake support plate. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6031 27. Remove the brake support plate from the vehicle. Remove the rubber plug(s) in the manual adjuster and lining inspection slot(s) as equipped, for use in the replacement support plate. Discard the support plate. 28. Insert the 4 hub/bearing mounting bolts into the holes in the flange of the rear axle. 29. Install the revised brake support plate, p/n 05016612/3AA on the 4 bolts inserted in the flange of the rear axle, make sure the park brake cable hole in the support plate faces toward the front of the vehicle. 30. Align the hub/bearing with the 4 mounting bolts and finger tighten the bolts into the hub/bearing. Tighten the 4 bolts in a crisscross pattern until the hub/bearing is fully seated into the flange of the rear axle. 31. Torque the 4 hub/bearing mounting bolts to 129 Nm (95 ft. lbs.). NOTE: FOR NS-VEHICLES BUILT PRIOR TO SEPT. 27, 1996 (MDH 0927XX) AT THE ST. LOUIS ASSEMBLY PLANT (LETTER "B" IN THE 11TH POSITION OF THE VIN) AND BUILT PRIOR TO OCT. 28 1996 (MDH 1028XX) AT THE WINDSOR ASSEMBLY PLANT (LETTER "R" IN THE 11TH POSITION OF THE VIN), THAT HAVE THEIR ORIGINAL REAR BRAKE COMPONENTS, IF THE REAR BRAKE SHOES REQUIRE REPLACEMENT, WHEEL CYLINDERS (13/16 IN.), P/N 04883830AA, MUST ALSO BE INSTALLED. IF TSB 05-06-96, 05-06-96 REV.A OR 05-01-97 HAVE BEEN PERFORMED ON THE VEHICLE, WHEEL CYLINDER REPLACEMENT IS NOT REQUIRED. 32. Apply a sealant such as Mopar RTV, p/n 05010884AA, or equivalent around the wheel cylinder opening in the revised brake support plate. 33. Attach the wheel cylinder to the revised brake support plate before the sealant cures, torque the 2 mounting bolts to 8 Nm (75 in. lbs.). 34. Install the brake tube into the wheel cylinder and torque the tube nut to 16 Nm (142 in. lbs.) 35. Install the rear wheel speed sensor if so equipped. CS/NS vehicles: torque the attaching bolt to 12 Nm (105 in. lbs.). 36. For GS/NS without ABS and all RS vehicles fill any existing gap between the bearing flange and the ABS sensor hole in the support plate with Mopar RTV sealant, p/n 05010884AA. 37. Install the rear park brake cable into its mounting hole in the brake support plate. 38. Install the park brake cable to the park brake actuator lever. 39. Lubricate the eight brake shoe contact areas on the support plate using the required special Mopar Brake Lubricant p/n 04796269. 40. Install the leading brake shoe, hold down, pin and spring onto the brake support plate. 41. Install the park brake actuator strut on the leading brake shoe. Then install the park brake actuator lever on the strut. 42. Install the automatic adjuster assembly on the leading brake shoe. Then install the trailing brake shoe on the park brake actuator lever and park brake actuator strut. Position the trailing brake shoe on the brake support plate. 43. Install the trailing brake shoe hold down, pin and spring onto the brake support plate. 44. Install the upper brake shoe to brake shoe return spring. CAUTION: WHEN INSTALLING THE TENSION CLIP ON THE AUTOMATIC ADJUSTER, THE CLIP MUST BE LOCATED ON THE THREADED AREA OF THE ADJUSTER ASSEMBLY. IF IT IS LOCATED ON THE NON-THREADED AREA OF THE ADJUSTER, THE FUNCTION OF THE AUTOMATIC ADJUSTER WILL BE AFFECTED. 45. Install the tension clip attaching the upper return spring to the automatic adjuster. 46. Install the lower brake shoe to brake shoe return springs. 47. Install the automatic adjuster lever on the leading brake shoe. 48. Install the actuating spring on the automatic adjuster lever and the leading brake shoe. 49. Verify the automatic adjuster lever has positive contact with the star wheel on the automatic adjuster assembly. 50. Repeat steps 8 through 48 for the other side rear brake assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 6032 51. When all components of both rear brake assemblies are correctly and fully installed, remove the locking pliers from the front park brake cable. 52. Adjust the rear brakes so they do not interfere with installing the brake drums. 53. Install both rear brake drums. Install the original drums as removed unless their condition justifies turning or replacement. 54. Install both rear tire/wheel assemblies. Torque the lug nuts using a crisscross pattern to 135 Nm (100 ft. lbs.). 55. Insert a thin flat blade screwdriver through the adjusting hole in the support plate until it is against the star wheel of the adjuster assembly. Move the handle of the screwdriver upward rotating the star wheel until slight drag is felt when the tire/wheel assembly is turned. 56. Insert a second screwdriver or piece of stiff wire into the brake adjusting hole and push against the adjuster lever to disengage it from the star wheel. Care should be taken not bend the adjusting lever or distort the lever spring. 57. While the adjuster lever is disengaged from the star wheel turn the star wheel just enough to eliminate the drag felt when the tire/wheel assembly is turned. 58. Install the adjusting/inspection hole rubber plug(s) saved in step 26 59. Repeat steps 55 through 58 for the other side rear brake. 60. Perform the base brake bleeding procedure described in the appropriate service manual. 61. Lower the vehicle to the floor. 62. Push the park brake pedal down fully and release to adjust the park brake cables. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 6033 Brake Shoe: Specifications Minimum Thickness Inspect brake lining for wear, shoe alignment, and or contamination from grease or brake fluid. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 6034 Brake Shoe: Adjustments ADJUSTMENT - REAR DRUM BRAKE SHOES NOTE: Normally, self-adjusting drum brakes do not require manual brake shoe adjustment. Although, in the event of a brake shoe replacement, it is advisable to make the initial adjustment manually to speed up the adjusting time. NOTE: Before raising the vehicle, verify the parking brake lever is fully released. 1. Raise the vehicle. 2. Remove rubber plug from rear brake adjusting hole in the rear brake support plate. 3. Insert a thin screwdriver through the adjusting hole in the support plate and against the star wheel of the adjusting screw. Move handle of the tool downward, rotating the star wheel until a slight drag is felt when tire and wheel assembly is rotated. 4. Insert a second thin screwdriver or piece of welding rod into brake adjusting hole and push the adjusting lever out of engagement with the star wheel. Care should be taken so as not to bend adjusting lever or distort lever spring. 5. While holding the adjusting lever out of engagement, back off the star wheel just enough to ensure a free wheel with no brake shoe drag. 6. Repeat the above adjustment at the other rear wheel. 7. Install the adjusting hole rubber plugs back in the rear brake support plates. 8. Lower the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 6035 Brake Shoe: Service and Repair REMOVAL - REAR DRUM BRAKE SHOES 1. Raise vehicle. 2. Remove the rear wheel and tire assemblies from the vehicle. 3. Remove rear brake drum to hub retaining clips (if equipped), then remove rear brake drums. NOTE: When creating slack in the park brake cables by locking out the automatic adjuster, (Fig. 18) be sure that the park brake pedal is in the released (most upward) position. 4. Create slack in the rear park brake cables. Slack is created by grabbing exposed section of front park brake cable and pulling it down and rearward. Slack is maintained in the park brake cable by installing a pair of locking pliers on the park brake cable just rearward of only the rear body outrigger bracket. (Fig. 18) 5. Remove adjustment lever spring (Fig. 19) from adjustment lever and front brake shoe. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 6036 6. Remove adjustment lever (Fig. 20) from leading brake shoe. 7. Remove the brake shoe to brake shoe lower return springs (Fig. 21) and (Fig. 22). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 6037 8. Remove the tension clip (Fig. 23) attaching the upper return spring to the automatic adjuster assembly. 9. Remove the brake shoe to brake shoe upper return spring (Fig. 24). 10. Remove the trailing brake shoe assembly to brake support plate hold down spring and pin (Fig. 25) from the brake shoe assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 6038 11. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating lever and park brake actuating strut (Fig. 26). Remove the automatic adjuster assembly from the leading brake shoe. 12. Remove the leading brake shoe assembly to brake support plate hold down spring and pin (Fig. 27) from the brake shoe. Remove the leading brake shoe from the brake support plate. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 6039 13. Remove the park brake actuator (Fig. 28) from the leading brake shoe and transfer to the replacement brake shoe. INSPECTION - REAR DRUM BRAKE SHOE LINING 1. Remove the tire and wheel assembly from the vehicle 2. Remove the rear brake adjusting hole plug found in the brake support. 3. Insert a thin screwdriver into brake adjusting hole to hold the adjusting lever away from the notches on the adjusting screw star wheel. 4. Insert Tool C-3784 into brake adjusting hole and engage notches of brake adjusting screw star wheel. Release brake by prying down with adjusting tool. 5. Remove the rear brake drum from the rear hub and bearing assembly. 6. Inspect brake lining for wear, shoe alignment, and or contamination from grease or brake fluid. INSTALLATION - REAR DRUM BRAKE SHOES 1. Lubricate the eight shoe contact areas on the support plate and anchor, (Fig. 29) using the required special Mopar Brake Lubricant or equivalent. 2. Install leading brake shoe on brake support plate. Install the leading brake shoe hold down spring and pin (Fig. 27) on the brake shoe. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 6040 3. Install the park brake actuator strut (Fig. 30) on the leading brake shoe. Then install the park brake actuator lever on the strut (Fig. 30). 4. Install the automatic adjuster screw on the leading brake shoe. Then install the trailing brake shoe on the park brake actuating lever and park brake actuating strut (Fig. 26). Position trailing brake shoe on brake support plate. 5. Install the brake shoe hold down pin and spring on the trailing brake shoe (Fig. 25). 6. Install the brake shoe to brake shoe upper return spring (Fig. 24). CAUTION: When installing the tension clip on the automatic adjuster, it must be located on only the threaded area of the adjuster assembly (Fig. 23). If it is located on a non-threaded area of the adjuster, the function of the automatic adjuster will be affected. 7. Install the tension clip (Fig. 23) attaching the upper return spring to the automatic adjuster assembly. 8. Install the brake shoe to brake shoe lower return springs on the brake shoes (Fig. 21) and (Fig. 22). 9. Install automatic adjustment lever on the leading brake shoe of the rear brake assembly (Fig. 20). 10. Install the actuating spring on the automatic adjustment lever and leading brake shoe assembly (Fig. 19). 11. Verify that the automatic adjuster lever has positive contact with the star wheel on the automatic adjuster assembly. 12. When all components of both rear brake assemblies are correctly and fully installed, remove the locking pliers from the front park brake cable. 13. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 14. Install the rear brake drums on the hubs. 15. Adjust rear brake shoes. 16. Install the wheel and tire assembly. 17. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 18. Lower the vehicle. 19. Push the parking brake lever (pedal) to the floor once and release pedal. This will automatically remove the slack from and correctly adjust the parking brake cables. 20. Road test vehicle. The automatic adjuster will continue the brake adjustment during the road test of the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair Wheel Cylinder: Service and Repair WHEEL CYLINDERS REMOVAL 1. Using a brake pedal depressor, move and secure brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of master cylinder when brake tube is remove from wheel cylinder. 2. Raise vehicle. 3. Remove wheel and tire assembly. 4. Disconnect brake tube from rear of wheel cylinder. Cap open ends 5. Remove brake drum. 6. Remove brake shoes from brake support plate (Discard if contaminated). 7. Remove the 2 bolts attaching the wheel cylinder to the brake support plate. 8. Remove the wheel cylinder from the brake support plate. INSPECTION With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel cylinders should be completely cleaned, inspected and new parts installed. If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake shoes must be replaced. INSTALLATION 1. Apply sealant such as Mopar Gasket-In-A-Tube or equivalent around the wheel cylinder opening in the brake support plate. 2. Install wheel cylinder onto brake support. Install and tighten the wheel cylinder to brake support plate attaching bolts to 8 Nm (75 inch lbs.) torque. 3. Install brake tube into wheel cylinder. Tighten tube nut to a torque of 17 Nm (145 inch lbs.) torque. 4. Install the rear brake shoes on the brake support plate. 5. Install brake drum. 6. Install wheel and tire. Install and tighten wheel lug nuts to 135 Nm (100 ft. lbs.). 7. Adjust drum brake shoes. 8. Remove brake pedal depressor tool. 9. Bleed the brake system as necessary. 10. Lower vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding Brake Bleeding: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE - MASTER CYLINDER BLEEDING CAUTION: When clamping master cylinder in vise, only clamp master cylinder by its mounting flange. Do not clamp master cylinder piston rod, reservoir, seal or body. 1. Clamp master cylinder in a vise. NOTE: Use correct bleeder tubes when bleeding master cylinder. Master cylinder outlet ports vary in size and type depending on whether master cylinder is for a vehicle equipped with ABS or not. ABS equipped master cylinders require the additional use of ISO style flare adapters supplied in Special Tool Package 8822 to be used in conjunction with Bleeder Tubes, Special Tool Package 8358. 2. Attach special tools for bleeding master cylinder in the following fashion: a. For non-ABS control equipped master cylinders, thread a Bleeder Tube, Special Tool 8358-1, into each outlet port. Tighten each tube to 17 Nm (145 inch lbs.) torque. Flex bleeder tubes and place open ends into mouth of fluid reservoir as far down as possible (Fig. 47). b. For ABS equipped master cylinders, thread one Adapter, Special Tool 8822-2, in each outlet port. Tighten Adapters to 17 Nm (145 inch lbs.) torque. Next, thread a Bleeder Tube, Special Tool 8358-1, into each Adapter. Tighten each tube to 17 Nm (145 inch lbs.) torque. Flex bleeder tubes and place open ends into mouth of fluid reservoir as far down as possible (Fig. 47). NOTE: Make sure open ends of bleeder tubes stay below surface of brake fluid once reservoir is filled to proper level. 3. Fill brake fluid reservoir with Mopar brake fluid or equivalent conforming to DOT 3 (DOT 4 and DOT 4+ are acceptable) specifications. Make sure fluid level is above tips of bleeder tubes in reservoir to ensure no air is ingested during bleeding. 4. Using a wooden dowel as a pushrod (Fig. 47), slowly depress master cylinder pistons, then release pressure, allowing pistons to return to released position. Repeat several times until all air bubbles are expelled. Make sure fluid level stays above tips of bleeder tubes in reservoir while bleeding. 5. Remove bleeder tubes from master cylinder outlet ports, then plug outlet ports and install fill cap on reservoir. 6. Remove master cylinder from vise. 7. Install master cylinder on vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 6049 Brake Bleeding: Service and Repair Base Brake System STANDARD PROCEDURE - BASE BRAKE BLEEDING NOTE: This bleeding procedure is only for the vehicle's base brakes hydraulic system. CAUTION: Before removing the master cylinder cover, thoroughly clean the cover and master cylinder fluid reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid reservoir. NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system. The use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic system. ^ Left Rear Wheel ^ Right Front Wheel ^ Right Rear Wheel ^ Left Front Wheel NOTE: When bleeding the brake system, some air may be trapped in the brake lines or valves far upstream, as much as ten feet from the bleeder screw (Fig. 1). Therefore, it is essential to have a fast flow of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out. The brakes may be manually bled or pressure bled. MANUAL BLEEDING PROCEDURE NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper. NOTE: To adequately bleed the brakes using the manual bleeding procedure the rear brakes must be correctly adjusted. Prior to the manual bleeding of the brake hydraulic system, correctly adjust the rear brakes. 1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened. 2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at least 1 full turn. When the bleeder screw opens the brake pedal will drop all the way to the floor. CAUTION: "Just cracking" the bleeder screw often restricts fluid flow, allowing only a slow, weak fluid discharge of fluid. This practice will NOT get all the air out. Make sure the bleeder is opened at least 1 full turn when bleeding. 3. Release the brake pedal only after the bleeder screw is closed. 4. Repeat steps 1 through 3, four or five times, at each bleeder screw in the proper sequence. This should pass a sufficient amount of fluid to expel all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 5. Check pedal travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Continue to bleed system as necessary. 6. Perform a final adjustment of the rear brake shoes (when applicable), then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. PRESSURE BLEEDING PROCEDURE CAUTION: Use bleeder tank Special Tool C-3496-B or equivalent with Adapter, Special Tool 6921, to pressurize the hydraulic system for bleeding. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 6050 Follow pressure bleeder manufacturer's instructions for use of pressure bleeding equipment. 1. Install the Adapter Master Cylinder Pressure Bleed Cap, Special Tool 6921 on the fluid reservoir of the master cylinder (Fig. 2). Attach the fluid hose from the pressure bleeder to the fitting on Special Tool 6921. 2. Attach a clear plastic hose to the bleeder screw at one wheel and feed the hose into a clear jar containing fresh brake fluid. 3. Open the left rear wheel bleeder screw at least one full turn or more to obtain an adequate flow of brake fluid. CAUTION: "Just cracking" the bleeder screw often restricts fluid flow, allowing only a slow, weak fluid discharge of fluid. This practice will NOT get all the air out. Make sure the bleeder is opened at least 1 full turn when bleeding. 4. After 4 to X ounces of brake fluid has been bled through the hydraulic system, and an air-free flow is maintained in the hose and jar, this will indicate a good bleed of the hydraulic system has been obtained. 5. Repeat the procedure at all the other remaining bleeder screws. 6. Check pedal travel. If pedal travel is excessive or has not been improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not enter the brake system through the master cylinder. 7. Perform a final adjustment of the rear brake shoes (when applicable), then test drive vehicle to be sure brakes are operating correctly and that pedal is solid. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Master Cylinder Bleeding > Page 6051 Brake Bleeding: Service and Repair Antilock Brake System STANDARD PROCEDURE - ANTILOCK BRAKE SYSTEM BLEEDING The base brake's hydraulic system must be bled anytime air enters the hydraulic system. The ABS though, particularly the ICU (HCU), should only need to be bled when the HCU is replaced or removed from the vehicle. The ABS must always be bled anytime it is suspected that the HCU has ingested air. Under most circumstances that require the bleeding of the brakes hydraulic system, only the base brake hydraulic system needs to be bled. When bleeding the ABS system, the following bleeding sequence must be followed to insure complete and adequate bleeding. 1. Make sure all hydraulic fluid lines are installed and properly torqued. 2. Connect the scan tool to the Data Link Connector. The connector is located under the lower steering column cover to the left of the steering column. 3. Using the scan tool, check to make sure the CAB (MK20e) or ABM (Mk25e) does not have any fault codes stored. If it does, clear them using the scan tool. WARNING: WHEN BLEEDING THE BRAKE SYSTEM WEAR SAFETY GLASSES. A CLEAR BLEED TUBE MUST BE ATTACHED TO THE BLEEDER SCREWS AND SUBMERGED IN A CLEAR CONTAINER FILLED PART WAY WITH CLEAN BRAKE FLUID. DIRECT THE FLOW OF BRAKE FLUID AWAY FROM YOURSELF AND THE PAINTED SURFACES OF THE VEHICLE. BRAKE FLUID AT HIGH PRESSURE MAY COME OUT OF THE BLEEDER SCREWS WHEN OPENED. 4. Bleed the base brake system using the standard pressure or manual bleeding procedure. 5. Using the scan tool, select ANTILOCK BRAKES, followed by MISCELLANEOUS, then BLEED BRAKES. Follow the instructions displayed. When the scan tool displays TEST COMPLETED, disconnect the scan tool and proceed. 6. Bleed the base brake system a second time. Check brake fluid level in the reservoir periodically to prevent emptying, causing air to enter the hydraulic system. 7. Fill the master cylinder reservoir to the full level. 8. Test drive the vehicle to be sure the brakes are operating correctly and that the brake pedal does not feel spongy. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Brake Caliper DISC BRAKE CALIPER - FRONT REMOVAL REMOVAL - FRONT DISC BRAKE CALIPER (CONTINENTAL TEVES BRAKES) 1. Depress the brake pedal past its first inch of travel and hold it in this position using a brake pedal depressor (holding) tool. This is done to isolate the master cylinder from the brake hydraulic system disallowing the brake fluid to completely drain out of the brake fluid reservoir. 2. Raise the vehicle. 3. Remove front wheel and tire assembly. 4. Remove the banjo bolt connecting the brake hose to the brake caliper. There are two washers (one on each side of the brake hose fitting) that will come off with the banjo bolt. Discard these washers. 5. Remove the 2 caliper guide pin bolts. 6. Remove the brake caliper from the adapter. REMOVAL - FRONT DISC BRAKE CALIPER (TRW BRAKES) 1. Using a brake pedal holding tool, depress the brake pedal past its first one inch of travel and hold it in this position. This will isolate the master cylinder from the brake hydraulic system and will not allow the brake fluid to drain out of the master cylinder reservoir when the lines are opened. 2. Raise the vehicle. 3. Remove the front tire and wheel assembly. 4. Remove the banjo bolt connecting the brake hose to the brake caliper (Fig. 31). There are two washers (one on each side of the flex hose fitting) that will come off with the banjo bolt. Discard the washers. 5. Remove the two brake caliper guide pin bolts (Fig. 31). 6. Remove the disc brake caliper from the disc brake adapter. DISASSEMBLY DISASSEMBLY - CALIPER GUIDE PIN BUSHINGS (CONTINENTAL TEVES BRAKES) Before disassembling the brake caliper, clean and inspect it. 1. Using your fingers, collapse one side of the rubber guide pin bushing. Pull the guide pin bushing out the other side of the brake caliper mounting boss. 2. Repeat this procedure on the remaining bushing. DISASSEMBLY - CALIPER PISTON AND SEAL WARNING: UNDER NO CONDITION SHOULD HIGH PRESSURE AIR EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. NOTE: Before disassembling the brake caliper, clean and inspect it. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6056 NOTE: The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of the vehicle's brake system. 1. Following the removal procedure in DISC BRAKE SHOES, remove the caliper from the brake rotor and hang the assembly on a wire hook away from rotor and body of the vehicle so brake fluid cannot get on these components. Remove the brake shoes, and place a small piece of wood between the piston and caliper fingers. 2. Carefully depress the brake pedal to hydraulically push piston out of its bore. Once completed, apply and hold down the brake pedal to any position beyond the first inch of pedal travel using a brake pedal holding tool. This will prevent the fluid in the master cylinder reservoir from completely draining out. 3. Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 4. Mount the caliper in a vise equipped with protective jaws. 5. Remove the piston dust boot from the caliper and discard. NOTE: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. 6. Using a soft tool such as a plastic trim stick, work the piston seal out of its groove in caliper piston bore (Fig. 32). Discard the old seal. 7. Clean the piston bore and drilled passage ways using alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 8. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. CLEANING - CALIPER WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. INSPECTION - CALIPER Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6057 Inspect the disc brake caliper for the following: ^ Brake fluid leaks in and around boot area and inboard lining ^ Ruptures, brittleness or damage to the piston dust boot ^ Damaged, dry or brittle guide pin dust boots If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. ASSEMBLY ASSEMBLY - CALIPER GUIDE PIN BUSHINGS (CONTINENTAL TEVES BRAKES) 1. Fold the guide pin bushing in half lengthwise. NOTE: To avoid damage to the bushing, do not use a sharp object to install the guide pin bushing. 2. Insert the folded bushing into the caliper mounting boss using your fingers from the rear of the caliper. 3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the caliper housing. The bushing flanges should be seated evenly on both sides of the bushing hole. 4. Lubricate inside surfaces of bushing using Mopar Dielectric Grease or equivalent. 5. Repeat the procedure for remaining bushing. ASSEMBLY - CALIPER PISTON AND SEAL NOTE: Never use an old piston seal. 1. Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore. The seal should be started at one area of the groove and gently worked around and into the groove (Fig. 33) using only your clean fingers to seat it. 2. Coat the new piston boot with clean brake fluid. 3. Position the dust boot over the piston after coating it with brake fluid. CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6058 4. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore (Fig. 34). 5. Position the dust boot into the counterbore of the caliper assembly piston bore. 6. Using a hammer and Installer, Special Tool C-4689 or C-4842 (depending on piston size), and Handle, Special Tool C-4171, drive the boot into the counterbore of the caliper as necessary (Fig. 35). 7. Reinstall the caliper on the vehicle and bleed the brakes as necessary. INSTALLATION INSTALLATION - FRONT DISC BRAKE CALIPER (CONTINENTAL TEVES BRAKES) CAUTION: TRW and Continental Teves brake calipers are not interchangeable. Each caliper is specifically designed for the unique brake system. If calipers are interchanged, improper performance, noise and increased stopping distance can occur. 1. Completely retract the caliper piston back into piston bore of the caliper. Use a C-clamp to retract the piston if necessary. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6059 CAUTION: Use care when installing the brake caliper assembly onto the steering knuckle, so that the seals on the caliper guide pin bushings do not get damaged by the steering knuckle bosses. 2. Carefully position the brake caliper and shoes over the brake rotor and adapter. 3. Install the caliper guide pin bolts and tighten to a torque of 35 Nm (26 ft. lbs.). Extreme caution should be taken not to cross thread the caliper guide pin bolts. 4. Install the anti-rattle clip on the outboard side of the caliper. Start the clip into the holes on the caliper, then stretch the clip legs past the abutments on the caliper adapter. CAUTION: When connecting the brake hose to the caliper, install new brake hose to caliper special copper washers. 5. Install the brake hose on the caliper. To do this, first place one NEW special fitting washer on each side of the hose fitting, then slide the banjo bolt through the fitting. Next, thread the banjo bolt into the threaded port on the rear of the brake caliper. Tighten the banjo bolt to a torque of 47 Nm (35 ft. lbs.). 6. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification, then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 7. Lower the vehicle. 8. Remove the brake pedal depressor (holding) tool. 9. Bleed the hydraulic brake circuit to the brake caliper. 10. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. INSTALLATION - FRONT DISC BRAKE CALIPER (TRW BRAKES) CAUTION: TRW and Continental Teves brake calipers are not interchangeable. Each caliper is specifically designed for the unique brake system. If calipers are interchanged, improper performance, noise and increased stopping distance can occur. 1. Completely retract the caliper piston back into the bore of the caliper. Use a C-clamp to retract the piston if necessary. Place a wood block over the piston before installing the C-clamp to avoid damaging the piston. CAUTION: Use care when installing the caliper onto the disc brake adapter to avoid damaging the boots on the caliper guide pins. 2. Install the disc brake caliper over the brake shoes on the brake caliper adapter. 3. Align the caliper guide pin bolt holes with the guide pins. Install the caliper guide pin bolts and tighten them to a torque of 35 Nm (26 ft. lbs.) (Fig. 31). 4. Install the banjo bolt connecting the brake hose to the brake caliper (Fig. 31). Install NEW copper washers on each side of the hose fitting as the banjo bolt is guided through the fitting. Thread the banjo bolt into the caliper and tighten it to a torque of 47 Nm (35 ft. lbs.). 5. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Remove the brake pedal holding tool. 8. Bleed the caliper as necessary. 9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoes. Disc Brake Caliper Adapter DISC BRAKE CALIPER ADAPTER REMOVAL - FRONT DISC BRAKE CALIPER ADAPTER 1. Raise vehicle. 2. Remove front wheel and tire assembly, disc brake caliper and brake shoes. 3. Remove two bolts fastening adapter to steering knuckle, then remove disc brake caliper adapter. INSTALLATION - FRONT DISC BRAKE CALIPER ADAPTER 1. Place adapter over brake rotor and align adapter mounting holes to knuckle. CAUTION: Adapter mounting bolts have a special Dacromet coating applied to resist corrosion. If mounting bolts need to be replaced, use only Mopar replacement parts. 2. Install adapter mounting bolts and tighten to 169 Nm (125 ft. lbs.) torque. 3. Install brake shoes, disc brake caliper and wheel and tire assembly. 4. Lower vehicle. 5. Pump the brake pedal several times to set the pads to the brake rotor. 6. Check and adjust brake fluid level as necessary. Disc Brake Caliper Guide Pins DISC BRAKE CALIPER GUIDE PINS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6060 REMOVAL - DISC BRAKE CALIPER GUIDE PINS (TRW BRAKES) 1. Raise the vehicle. 2. Remove the front tire and wheel assembly. 3. Remove the two brake caliper guide pin bolts (Fig. 42). 4. Remove the disc brake caliper from the disc brake caliper adapter and hang it out of the way using wire or a bungee cord. Use care not to overextend the brake hose when doing this. 5. Remove the guide pins and boots from the adapter as shown (Fig. 43). INSTALLATION - DISC BRAKE CALIPER GUIDE PINS (TRW BRAKES) 1. Lubricate the guide pins and inside the boots with the packet supplied with the service kit, Sytheso GLK-1 lubricant or equivalent. 2. Install the guide pins and boots in the adapter as shown (Fig. 43). The boots have grooves built into their inner lips to fit onto the pins and adapter. CAUTION: Use care when installing the caliper onto the disc brake adapter to avoid damaging the boots on the caliper guide pins. 3. Install the disc brake caliper over the brake shoes on the brake caliper adapter. 4. Align the caliper guide pin bolt holes with the guide pins. Install the caliper guide pin bolts and tighten them to a torque of 35 Nm (26 ft. lbs.) (Fig. 42). 5. Install the tire and wheel assembly. Tighten the wheel mounting nuts to a torque of 135 Nm (100 ft. lbs.). 6. Lower the vehicle. 7. Pump the brake pedal several times before moving the vehicle to set the shoes to the brake rotor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6061 Brake Caliper: Service and Repair Rear DISC BRAKE CALIPER REAR REMOVAL - REAR DISC BRAKE CALIPER NOTE: Handling of the rotor and caliper, must be done in such a way as to avoid damage to the rotor and scratching or nicking of lining on the brake shoes. 1. Depress the brake pedal past its first inch of travel and hold it in this position using a brake pedal depressor (holding) tool. This is done to isolate the master cylinder from the brake hydraulic system disallowing the brake fluid to completely drain out of the brake fluid reservoir. 2. Raise the vehicle. 3. Remove rear wheel and tire assembly from vehicle. 4. Remove the banjo bolt connecting the brake hose to the brake caliper. There are two washers (one on each side of the brake hose fitting) that will come off with the banjo bolt. Discard these washers. 5. Remove the disc brake caliper to adapter guide pin bolts (Fig. 36). 6. Remove rear caliper from adapter using the following procedure. First rotate front of caliper up from the adapter. Then pull the rear of the caliper and the outboard brake shoe anti-rattle clip out from under the rear abutment on the adapter (Fig. 37). 7. If the brake rotor requires removal, it can now be removed by first removing the retainer clips from the wheel mounting studs, then pulling the rotor straight off the studs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6062 DISASSEMBLY - CALIPER PISTON AND SEAL WARNING: UNDER NO CONDITION SHOULD HIGH PRESSURE AIR EVER BE USED TO REMOVE A PISTON FROM A CALIPER BORE. PERSONAL INJURY COULD RESULT FROM SUCH A PRACTICE. NOTE: Before disassembling the brake caliper, clean and inspect it. NOTE: The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of the vehicle's brake system. 1. Following the removal procedure in DISC BRAKE SHOES, remove the caliper from the brake rotor and hang the assembly on a wire hook away from rotor and body of the vehicle so brake fluid cannot get on these components. Remove the brake shoes, and place a small piece of wood between the piston and caliper fingers. 2. Carefully depress the brake pedal to hydraulically push piston out of its bore. Once completed, apply and hold down the brake pedal to any position beyond the first inch of pedal travel using a brake pedal holding tool. This will prevent the fluid in the master cylinder reservoir from completely draining out. 3. Disconnect the brake fluid flex hose from the caliper assembly and remove it from the vehicle. CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion. 4. Mount the caliper in a vise equipped with protective jaws. 5. Remove the piston dust boot from the caliper and discard. NOTE: Do not use a screw driver or other metal tool for seal removal. Using such tools can scratch the bore or leave burrs on the seal groove edges. 6. Using a soft tool such as a plastic trim stick, work the piston seal out of its groove in caliper piston bore (Fig. 38). Discard the old seal. 7. Clean the piston bore and drilled passage ways using alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. 8. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can usually be cleared of the light scratches or corrosion using crocus cloth. CLEANING - CALIPER WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CONTAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE LININGS. BREATHING EXCESSIVE CONCENTRATIONS OF ASBESTOS FIBERS CAN CAUSE SERIOUS BODILY HARM. EXERCISE CARE WHEN SERVICING BRAKE PARTS. DO NOT SAND OR GRIND BRAKE LINING UNLESS EQUIPMENT USED IS DESIGNED TO CONTAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE PARTS WITH COMPRESSED AIR OR BY DRY BRUSHING. CLEANING SHOULD BE DONE BY DAMPENING THE BRAKE COMPONENTS WITH A FINE MIST OF WATER, THEN WIPING THE BRAKE COMPONENTS CLEAN WITH A DAMPENED CLOTH. DISPOSE OF CLOTH AND ALL RESIDUE CONTAINING ASBESTOS FIBERS IN AN IMPERMEABLE CONTAINER WITH THE APPROPRIATE LABEL. FOLLOW PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6063 ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR THE HANDLING, PROCESSING, AND DISPOSING OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS. To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar Non-Chlorinated Brake Parts Cleaner. Never use gasoline, kerosene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper. These fluids will damage rubber cups and seals. INSPECTION - CALIPER Inspect the disc brake caliper for the following: ^ Brake fluid leaks in and around boot area and inboard lining ^ Ruptures, brittleness or damage to the piston dust boot ^ Damaged, dry or brittle guide pin dust boots If caliper fails inspection, disassemble and recondition caliper, replacing the seals and dust boots. ASSEMBLY - CALIPER PISTON AND SEAL NOTE: Never use an old piston seal. 1. Dip the new piston seal in clean brake fluid and install it in the groove of the caliper bore. The seal should be started at one area of the groove and gently worked around and into the groove (Fig. 39) using only your clean fingers to seat it. 2. Coat the new piston boot with clean brake fluid. 3. Position the dust boot over the piston after coating it with brake fluid. CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cocking and binding of the piston. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6064 4. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore (Fig. 40). 5. Position the dust boot into the counterbore of the caliper assembly piston bore. 6. Using a hammer and Installer, Special Tool C-4689 or C-4842 (depending on piston size), and Handle, Special Tool C-4171, drive the boot into the counterbore of the caliper as necessary (Fig. 41). 7. Reinstall the caliper on the vehicle and bleed the brakes as necessary. INSTALLATION - REAR DISC BRAKE CALIPER 1. Completely retract caliper piston back into piston bore of the caliper. 2. If removed, install the brake rotor on the hub, making sure it is squarely seated on the face of the hub. CAUTION: Use care when installing the caliper assembly onto the adapter, so the caliper guide pin bushings do not get damaged by the mounting bosses. 3. Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse procedure for removal (Fig. 37). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 6065 CAUTION: When installing guide pin bolts extreme caution should be taken not to cross-thread the caliper guide pin bolts. 4. Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 35 Nm (26 ft. lbs.). CAUTION: When connecting the brake hose to the caliper, install new brake hose to caliper special washers. 5. Install the brake hose on the caliper. To do this, first place one NEW special copper washer on each side of the hose fitting, then slide the banjo bolt through the fitting. Next, thread the banjo bolt into the threaded port on the rear of the brake caliper. Tighten the banjo bolt to a torque of 47 Nm (35 ft. lbs.). 6. Install the wheel and tire assembly. 7. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 8. Lower the vehicle. 9. Remove the brake pedal depressor (holding) tool. 10. Bleed the hydraulic brake circuit to the brake caliper. 11. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 6070 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 6071 Brake Fluid: Specifications BRAKE FLUID Specification ........................................................................................................................................ .................................................................. DOT 3 * If DOT 3 brake fluid is not available, DOT 4 or DOT 4+ is acceptable. Standard .............................................................................................................................................. ........................................................... SAE J1703 NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 6072 Brake Fluid: Testing and Inspection DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brake hydraulic unit and all hydraulic fluid hoses. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 6073 Brake Fluid: Service and Repair STANDARD PROCEDURE - BRAKE FLUID LEVEL CHECKING Check master cylinder reservoir fluid level a minimum of twice annually. Fluid reservoirs are marked with the words FULL and ADD to indicate proper brake fluid fill level of the master cylinder. If necessary, add brake fluid to bring the level to the bottom of the FULL mark on the side of the master cylinder fluid reservoir. Use only Mopar brake fluid or equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications. DO NOT use brake fluid with a lower boiling point, as brake failure could result during prolonged hard braking. Use only brake fluid that was stored in a tightly sealed container. DO NOT use petroleum-based fluid because seal damage will result. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid etc. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Left Side Engine Compartment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6077 Brake Fluid Level Sensor/Switch: Description and Operation BRAKE FLUID LEVEL SWITCH DESCRIPTION The brake fluid level switch is located in the brake fluid reservoir of the master cylinder (Fig. 3). OPERATION The purpose of the brake fluid level switch is to provide the driver with an early warning that the brake fluid level in the master cylinder fluid reservoir has dropped below a normal level. This may indicate: ^ Abnormal loss of brake fluid in the master cylinder fluid reservoir resulting from a leak in the hydraulic system. ^ Brake shoe linings which have worn to a point requiring replacement. As the brake fluid drops below the minimum level, the brake fluid level switch closes to complete the red BRAKE warning indicator (lamp) circuit. This will turn on the red BRAKE warning indicator. The master cylinder fluid reservoir should be checked and refilled to the Full mark with DOT 3 brake fluid. If the brake fluid level has dropped below the add line in the master cylinder fluid reservoir, the entire brake hydraulic system should be checked for evidence of a leak. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6078 Brake Fluid Level Sensor/Switch: Service and Repair BRAKE FLUID LEVEL SWITCH REMOVAL 1. Remove wiring harness connector from brake fluid reservoir level switch (Fig. 3). 2. Using fingers, compress the retaining tabs on the opposite end of brake fluid level switch. 3. With retaining tabs compressed, grasp the connector end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. INSTALLATION 1. Insert brake fluid level switch into left side of brake fluid reservoir. Be sure switch is pushed in until retaining tabs lock it to brake fluid reservoir. 2. Connect vehicle wiring harness connector to brake fluid level switch (Fig. 3). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams Brake Fluid Level Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Description and Operation Brake Hose/Line: Description and Operation BRAKE LINES DESCRIPTION - BRAKE TUBES AND HOSES The brake tubes are steel with a corrosion-resistant nylon coating applied to the external surfaces. The flex hoses are made of reinforced rubber with fittings at each end. The primary and secondary brake tubes leading from the master cylinder to the ABS ICU Hydraulic Control Unit (HCU) or the non-ABS junction block have a special flexible section. This flexible section is required due to cradle movement while the vehicle is in motion (The ICU and non-ABS junction block are mounted to the cradle). If replacement of these lines is necessary, only the original factory brake line containing the flexible section must be used. OPERATION - BRAKE TUBES AND HOSES The purpose of the chassis brake tubes and flex hoses is to transfer the pressurized brake fluid developed by the master cylinder to the wheel brakes of the vehicle. The flex hoses are made of rubber to allow for the movement of the vehicle's suspension. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation Brake Proportioning/Combination Valve: Description and Operation DESCRIPTION - PROPORTIONING VALVE (HEIGHT SENSING) NOTE: Only vehicles without antilock brakes (ABS) have a proportioning valve. Vehicles with ABS utilize electronic brake distribution which is controlled through the ABS integrated control unit. Vehicles not equipped with ABS use a height sensing proportioning valve. It is mounted to the body of the vehicle above the rear axle (Fig. 80). It has an actuator lever that attaches to the rear axle and moves with the axle to help the valve sense the vehicle height. CAUTION: The height sensing proportioning valve is not adjustable. No attempt should be made to adjust it. It is replaced as a complete assembly. CAUTION: The use of after-market load leveling or load capacity increasing devices on this vehicle are prohibited. Using air shock absorbers or helper springs on this vehicle will cause the height sensing proportioning valve to inappropriately reduce the hydraulic pressure to the rear brakes. This inappropriate reduction in hydraulic pressure potentially could result in increased stopping distance of the vehicle. OPERATION - PROPORTIONING VALVE (HEIGHT SENSING) Vehicles not equipped with ABS use a height sensing proportioning valve. The height sensing proportioning valve operates similarly to a standard proportioning valve in the following way. As hydraulic pressure is applied to the valve, full input hydraulic pressure is supplied to the rear brakes up to a certain pressure point, called the split point. Beyond the split point, the proportioning valve reduces the amount of hydraulic pressure to the rear brakes according to a given ratio. Thus, on light brake applications, approximately equal hydraulic pressure will be transmitted to both the front and rear brakes. Upon heavier brake applications, the hydraulic pressure transmitted to the rear brakes will be lower than the front brakes. This will prevent premature rear wheel lockup and skid. Here is how the height sensing proportioning valve differs from a standard proportioning valve. As the height of the rear suspension changes, the height sensing portion of the proportioning valve changes the split point of the proportioning valve. When the height of the rear suspension is low, the proportioning valve interprets this as extra load and the split point of the proportioning valve is raised to a higher pressure to allow for more rear braking. When the height of the rear suspension is high, the proportioning valve interprets this as a light load and the split point of the proportioning valve is lowered to a lower pressure and rear braking is reduced. The height sensing proportioning valve regulates the pressure by sensing the load condition of the vehicle through the movement of the proportioning valve actuator lever (Fig. 80). As the position of the rear axle changes, depending on the load the vehicle is carrying, the movement is transferred to the proportioning valve. The proportioning valve adjusts the hydraulic pressure accordingly. The height sensing proportioning valve allows the brake system to maintain the optimal front to rear brake balance regardless of the vehicle load condition. Under a light load condition, hydraulic pressure to the rear brakes is minimized. As the rear load condition increases, so does the hydraulic pressure to the rear brakes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 6088 Brake Proportioning/Combination Valve: Testing and Inspection DIAGNOSIS AND TESTING - PROPORTIONING VALVE (HEIGHT SENSING) CAUTION: The use of aftermarket load leveling or load capacity increasing devices on this vehicle is prohibited. Using air shock absorbers or helper springs on this vehicle will cause the height sensing proportioning valve to inappropriately reduce the hydraulic pressure to the rear brakes. This inappropriate reduction in hydraulic pressure potentially could result in increased stopping distance of the vehicle. When a premature rear wheel skid is obtained on a brake application, it may be an indication that the hydraulic pressure to the rear brakes is above the specified output from the proportioning valve. This condition indicates a possible malfunction of the height sensing proportioning valve, which will require testing to verify that it is properly controlling the hydraulic pressure allowed to the rear brakes. Premature rear wheel skid may also be caused by contaminated front or rear brake linings. Prior to testing a proportioning valve for function, check that all tire pressures are correct. Also, ensure the front and rear brake linings are in satisfactory condition. It is also necessary to verify that the brakes shoe assemblies on a vehicle being tested are either original equipment manufacturers (OEM) or original replacement brake shoe assemblies meeting the OEM lining material specification. This vehicles brake system is not balanced for aftermarket brake shoe assembly lining material. If both front and rear brakes check OK, proceed with the following test procedure for the height sensing proportioning valve. 1. Road test the vehicle to determine which rear wheel brake is exhibiting premature wheel skid. 2. Raise vehicle. 3. Remove the chassis brake tube going to the rear brake in question at the proportioning valve. Remove the chassis brake tube coming from the junction block at the proportioning valve (Fig. 81). 4. Install the appropriate fittings from Pressure Test Fittings, Special Tool 6833, into the open ports of the proportioning valve. 5. Install the previously removed brake lines into the Pressure Test Fittings. Tighten all tube nuts to 17 Nm (145 inch lbs.). 6. Install a pressure gauge from Gauge Set, Special Tool C-4007-A into the open port on each pressure test fitting. Bleed air out of hose from pressure test fittings to pressure gauges at the pressure gauges. Then bleed air out of the brake line being tested at that rear wheel brake bleeder. NOTE: Actuator rod is a linear spring and is meant to flex by design. When rod is raised, it will have some curvature to it. 7. Remove the screw fastening the proportioning valve actuator rod bracket to the rear axle. Raise the actuator lever to the full-upward position and hold it there. 8. With the aid of a helper, apply pressure to the brake pedal until a pressure of 6895 kPa (1000 psi) is obtained on the proportioning valve inlet gauge. Then, based on the type of brake system the vehicle is equipped with and the pressure specification shown on the following table, compare the pressure reading on the outlet gauge to the specification. If outlet pressure at the proportioning valve is not within specification when required inlet pressure is obtained, replace the proportioning valve. CAUTION: Do not attempt to adjust the height sensing proportioning valve. If found to be defective, replace the valve. 9. Remove the pressure test fittings and pressure gauges from the proportioning valve. 10. Install the chassis brake lines in the correct ports of the proportioning valve. Tighten all tube nuts to 17 Nm (145 inch lbs.). 11. If necessary, repeat the above steps on the remaining side of the proportioning valve which control the other rear wheel brake. 12. Attach the actuator lever and bracket to the rear axle. 13. Bleed rear brakes. 14. Road test vehicle. PROPORTIONING VALVE SPECIFICATIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 6089 Brake Proportioning/Combination Valve: Service and Repair REMOVAL - PROPORTIONING VALVE (HEIGHT SENSING) 1. Using a brake pedal depressor, move and lock the brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the proportioning valve. 2. Raise vehicle. CAUTION: Before removing the brake tubes from the proportioning valve, the proportioning valve and the brake tubes must be thoroughly cleaned. This is required to prevent contamination from entering the proportioning valve or the brake tubes. 3. Remove the four brake tubes from the inlet and outlet ports of the proportioning valve (Fig. 81). 4. Remove the two bolts attaching the proportioning valve and bracket to the vehicle (Fig. 81). 5. Slide the bracket out from under rear track bar bracket. Lower the valve down enough to pull its actuator rod out of the axle bracket and remove the proportioning valve from the vehicle. INSTALLATION - PROPORTIONING VALVE (HEIGHT SENSING) 1. Install the end of the actuator rod through the axle bracket grommet and slide the proportioning valve bracket under the rear track bar body bracket (Fig. 81). 2. Install the proportioning valve attaching bolts (Fig. 81). Tighten the attaching bolts to a torque of 54 Nm (40 ft. lbs.). 3. Install the four chassis brake lines into the inlet and outlet ports of the proportioning valve (Fig. 81). Tighten all tube nuts to a torque of 17 Nm (145 inch lbs.). CAUTION: The height sensing proportioning valve is not adjustable. No attempt should be made to adjust it. 4. Bleed the brake system thoroughly to ensure that all air has been expelled from the hydraulic system. 5. Lower the vehicle to the ground. 6. Road test the vehicle to verify proper operation of the brake system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > System Description and Operation Hydraulic Control Assembly - Antilock Brakes: Description and Operation System Description and Operation MK20E DESCRIPTION - MK20e On vehicles equipped with the MK20e ABS, the hydraulic control unit (HCU) is mounted to the CAB as part of the ICU (Fig. 6). The HCU controls the flow of brake fluid to the brakes using a series of valves and accumulators. A pump/motor is mounted on the HCU to supply build pressure to the brakes during an ABS stop. OPERATION - HYDRAULIC CIRCUITS AND VALVES - MK20e NOTE: The following applies for Mark 20e ABS only. The hydraulic fluid control valves control the flow of pressurized brake fluid to the wheel brakes during the different modes of ABS braking. The following paragraphs explain how this works. For purposes of explanation only, it is assumed that only the right front wheel is experiencing antilock braking; the following diagrams show only the right front wheel in an antilock braking operation. NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 6094 The hydraulic diagram (Fig. 8) shows the vehicle in the normal braking mode of the base brake hydraulic system. The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle. The driver is applying the brake pedal which builds pressure in the brake hydraulic system to engage the brakes and stop the vehicle. ABS PRIMARY HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 6095 The hydraulic diagram (Fig. 9) shows the vehicle in the ABS braking mode. The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding. ^ The normally open and normally closed valves modulate (build/decay) the brake hydraulic pressure as required. ^ The pump/motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits. ^ The brake fluid is routed to either the master cylinder or the wheel brake depending on the position of the normally open valve. ABS SECONDARY HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 6096 The hydraulic diagram (Fig. 10) shows the vehicle in the ABS braking mode. The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding. ^ The normally open and normally closed valves modulate (build/decay) the brake hydraulic pressure as required. ^ The pump/motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits. ^ The brake fluid will then be routed to either the master cylinder or the wheel brake depending on the position of the normally open valve. ^ In the secondary circuit, 1.2 cc brake fluid is taken in by the lip seal saver to protect the lip seals on the master cylinder piston. NORMAL BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 6097 The hydraulic diagram (Fig. 11) shows a vehicle with traction control in the normal braking mode. The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle. The driver is applying the brake pedal which builds pressure in the brake hydraulic system to engage the brakes and stop the vehicle. the hydraulic shuttle valve closes with every brake pedal application so pressure is not created at the inlet to the pump/motor. ABS BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 6098 The hydraulic diagram (Fig. 12) shows the vehicle in the ABS braking mode. The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding. ^ The hydraulic shuttle valve closes upon brake application so that the pump/motor cannot siphon brake fluid from the master cylinder. ^ The normally open and normally closed valves modulate (build/decay) the brake hydraulic pressure as required. ^ The pump/motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits. ^ The brake fluid is routed to either the master cylinder or the wheel brake depending on the position of the normally open valve. ABS TRACTION CONTROL HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 6099 The hydraulic diagram (Fig. 13) shows the vehicle in the ABS braking mode. The diagram shows a drive wheel is spinning and brake pressure is required to reduce its speed. ^ The normally open ASR valve is energized to isolate the brake fluid being pumped from the master cylinder and to isolate the driven wheel. ^ The normally open ASR valve bypasses the pump output back to the master cylinder at a fixed pressure setting. ^ The normally open and normally closed valves modulate (build/decay) the brake pressure as required to the spinning wheel. MK25E DESCRIPTION - MK25E Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 6100 On Later Launch production vehicles (which are equipped with the MK25e ABS), the hydraulic control unit (HCU) is mounted to the ABM as part of the ICU (Fig. 7). The HCU controls the flow of brake fluid to the brakes using a series of valves and accumulators. A pump/motor is mounted on the HCU to supply build pressure to the brakes during an ABS stop. OPERATION - HYDRAULIC CIRCUITS AND VALVES - MK25e NOTE: The following applies for MK25e ABS only. The hydraulic fluid control valves within the HCU control the flow of pressurized brake fluid to the wheel brakes during the different modes of ABS braking and traction control. The following paragraphs explain how this works. For purposes of explanation only, the following diagrams show only one hydraulic circuit, the Right Front wheel braking circuit. NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 6101 The hydraulic diagram shows the vehicle in the normal braking mode of the base brake hydraulic system (Fig. 14). The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle. The driver is applying the brake pedal which builds pressure in the brake hydraulic system to engage the brakes and stop the vehicle. ABS HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 6102 The hydraulic diagram shows the vehicle in the ABS braking mode (Fig. 15). The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding. ^ The normally open and normally closed valves modulate (build/decay) the brake hydraulic pressure as required. ^ The pump/motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits. ^ The brake fluid is routed to either the master cylinder or the wheel brake depending on the position of the normally open valve. NORMAL BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 6103 The hydraulic diagram shows a vehicle with traction control in the normal braking mode (Fig. 16). The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle. The driver is applying the brake pedal which builds pressure in the brake hydraulic system to engage the brakes and stop the vehicle. The hydraulic shuttle valve closes with every brake pedal application so pressure is not created at the inlet to the pump/motor. ABS BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 6104 The hydraulic diagram shows the vehicle in the ABS braking mode (Fig. 17). The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding. ^ The hydraulic shuttle valve closes upon brake application so that the pump/motor cannot siphon brake fluid from the master cylinder. ^ The normally open and normally closed valves modulate (build/decay) the brake hydraulic pressure as required. ^ The pump/motor is switched on so that the brake fluid from the low pressure accumulators is returned to the master cylinder circuits. ^ The brake fluid is routed to either the master cylinder or the wheel brake depending on the position of the normally open valve. ABS TRACTION CONTROL HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 6105 The hydraulic diagram shows the vehicle in the traction control (TC) mode (Fig. 18). The diagram shows a drive wheel is spinning and brake pressure is required to reduce its speed. ^ The normally open TC (ASR) valve is energized to isolate the brake fluid being pumped from the master cylinder and to isolate the driven wheel. ^ The normally open TC (ASR) valve bypasses the pump output back to the master cylinder at a fixed pressure setting. ^ The normally open and normally closed valves modulate (build/decay) the brake pressure as required to the spinning wheel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 6106 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control Unit (HCU) HYDRAULIC CONTROL UNIT The hydraulic control unit (HCU) contains the valve block assembly, and pump/motor assembly The HCU is attached to the CAB/ABM. Valve Block Assembly: The valve block assembly contains valves with four inlet valves and four outlet valves. The inlet valves are spring-loaded in the open position and the outlet valves are spring loaded in the closed position. During an antilock stop, these valves are cycled to maintain the proper slip ratio for each wheel. If a wheel detects slip, the inlet valve is closed to prevent and further pressure increase. Then the outlet valve is opened to release the pressure to the accumulators until the wheel is no longer slipping. Once the wheel is no longer slipping, the outlet valve is closed and the inlet valve is opened to reapply pressure. If the wheel is decelerating within its predetermined limits (proper slip ratio), the inlet valve will close to hold the pressure constant. On vehicles which are equipped with a traction control system, there are four additional valves, two isolate the master cylinder and two shuttle. During a traction control event the brakes are applied to reduce wheel slippage. Pump Motor Assembly: The pump motor assembly provides the extra amount of fluid needed during antilock braking. The pump is supplied fluid that is released to the accumulators when the outlet valve is opened during an antilock stop. The pump is also used to drain the accumulator circuits after the antilock stop is complete. The pump is operated by an integral electric motor. This motor is controlled by the CAB/ABM. The CAB/ABM may turn on the pump motor when an antilock stop is detected. The pump continues to run during the antilock stop and is turned off after the stop is complete. Under some conditions, the pump motor will run to drain the accumulators during the next drive off. The CAB/ABM monitors the pump motor operation internally. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 6107 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Integrated Control Unit (ICU) MK20E INTEGRATED CONTROL UNIT (ICU) MK20E DESCRIPTION The hydraulic control unit (HCU) and the controller antilock brake (CAB) used with this antilock brake system are combined (integrated) into one unit, which is called the integrated control unit (ICU) (Fig. 19). Depending on whether the vehicle is Left-Hand Drive (LHD) or Right-Hand-Drive (RHD), the integrated control unit (ICU) is located in one of two locations. On LHD models, the ICU (and mounting bracket) is mounted to the front suspension cradle/crossmember below the master cylinder (Fig. 20). On RHD models, the ICU is located behind the front suspension cradle/crossmember on the left side of the vehicle. Two different ICU's (HCU and CAB) are used on this vehicle depending on whether or not the vehicle is equipped with traction control. The HCU on a vehicle equipped with traction control has a valve block that is approximately one inch longer than a HCU on a vehicle that is equipped with ABS only. The ABS-only ICU consists of the following components: the CAB, eight (build/decay) solenoid valves (four inlet valves and four outlet valves), valve block, fluid accumulators, a pump, and an electric motor. The ABS-with traction control ICU consists of the following components: the CAB, eight (build/decay) solenoid valves (four inlet valves and four outlet valves), two traction control (ASR) valves, two hydraulic shuttle valves, valve block, fluid accumulators, a pump, and an electric motor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > System Description and Operation > Page 6108 The replaceable components of the ICU are the HCU and the CAB. No attempt should be made to service any individual components of the HCU or CAB. OPERATION For information of the ICU, refer to these individual components of the ICU: ^ CONTROLLER ANTILOCK BRAKE (CAB) ^ HYDRAULIC CONTROL UNIT (HCU) MK25E INTEGRATED CONTROL UNIT (ICU) - MK25E DESCRIPTION The Hydraulic Control Unit (HCU) and the Antilock Brake Module (ABM) used with this antilock brake system are combined (integrated) into one unit, which is called the Integrated Control Unit (ICU) (Fig. 33). The ICU is located below the master cylinder in the engine compartment. It is mounted to the front suspension cradle/crossmember. The ABS ICU consists of the following components: the ABM, eight (build/decay) solenoid valves (four inlet valves and four outlet valves) and one hydraulic pump motor. The ABS ICU with traction control consists of the following components: the ABM, eight (build/decay) solenoid valves (four inlet valves and four outlet valves), two master cylinder isolation valves, two low pressure feed valves and one hydraulic pump motor. The replaceable components of the ICU are the HCU and the ABM. No attempt should be made to service any individual components of the HCU or ABM. OPERATION For information of the ICU, refer to these individual components of the ICU: ^ ANTILOCK BRAKE MODULE (ABM) ^ HYDRAULIC CONTROL UNIT (HCU) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation Hydraulic Control Assembly - Antilock Brakes: Service and Repair ICU - Removal and Installation LHD INTEGRATED CONTROL UNIT (ICU) MK20E REMOVAL - LHD 1. Disconnect the negative (ground) cable from the battery and isolate cable. 2. Remove the battery shield. 3. Remove the battery. 4. Disconnect the vacuum hose connector at the tank built into the battery tray. 5. Remove the screw securing the engine coolant filler neck to the battery tray. 6. Remove the battery tray. 7. Using a brake pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This will prevent brake fluid from draining out of the master cylinder once the brake tubes are removed from the HCU. CAUTION: Do not apply a 12-volt power source to any terminals of the 24-way CAB connector when disconnected. 8. Disconnect the wiring harness connector from the speed control servo. 9. Remove the speed control servo mounting nuts and move the servo out of the way. 10. Disconnect the 24-way connector from the CAB. To disconnect the 24-way connector, grasp the lock on the 24-way connector and pull it as far up as possible. This will unlock the 24-way connector from the socket on the CAB. CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the ports of HCU or entering the brake tubes. 11. Thoroughly clean all surfaces of the ICU and brake tube nuts. Use only a solvent such as Mopar Brake Parts Cleaner or equivalent to clean the ICU. 12. Remove the brake tubes (4) from the outlet ports on the HCU (Fig. 21) 13. Remove the primary and secondary brake tubes from the inlet ports on the HCU (Fig. 21). 14. Center and prop the steering wheel. 15. Remove the pinch bolt and disconnect the steering shaft coupling. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 6111 16. If equipped, remove the two clips securing silencer to dash seal (Fig. 22). Remove silencer. 17. Remove the three screws securing the dash seal (Fig. 22). Remove seal. 18. Remove the 3 bolts attaching the ICU to its mounting bracket (Fig. 23). 19. Remove ICU from the vehicle through engine compartment. 20. If required, to separating the CAB from the HCU. INSTALLATION - LHD 1. Place the ICU in its bracket below the master cylinder. Start the upper mounting bolt to hold it in place. 2. Inside the vehicle, install the remaining 2 mounting bolts attaching the ICU to the mounting bracket (Fig. 23). Tighten all 3 mounting bolts to a torque of 11 Nm (97 inch lbs.). 3. Install the dash seal and three mounting screws (Fig. 22). 4. If equipped, install the silencer on top of the dash seal (Fig. 22). 5. Connect the steering shaft coupling and install the pinch bolt (Fig. 22). Tighten the pinch bolt to 28 Nm (250 inch lbs.). 6. Remove the steering wheel holder. CAUTION: Because of the flexible section in the primary and secondary brake tubes, the brake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other or other vehicle components when installed. Also, after the brake tubes are installed on the HCU, ensure all spacer clips are reinstalled on the brake tubes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 6112 7. Install the primary and secondary brake tubes into their correct port locations on the HCU valve block (Fig. 21). Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). CAUTION: When installing the chassis brake tubes on the HCU valve block, they must be located correctly in the valve block to ensure proper ABS operation. NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the CAB. 8. Install the (4) chassis brake tubes into their correct port locations on the HCU valve block as shown (Fig. 21). Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). NOTE: Before installing the 24-way connector in the CAB be sure the seal is properly installed in the connector. 9. Install the 24-way connector on the CAB by, first, positioning the 24-way connector in the socket of the CAB and carefully pushing it down as far as possible. Once connector is fully seated by hand into the CAB socket, push down on connector lock. This will pull the connector into the socket of the CAB and lock it in the installed position. 10. Install any routing clips on the brake tubes. 11. Remove the brake pedal holder. 12. Install the speed control servo with its mounting nuts. 13. Connect the wiring harness to the speed control servo. 14. Install the battery tray. 15. Install the screw securing the coolant filler neck to the battery tray. 16. Reconnect the vacuum hose connector at the tank built into the battery tray. 17. Install the battery. 18. Install the battery shield. 19. Remove the brake pedal holder. 20. Connect negative cable back on negative post of the battery. 21. Bleed the Base and ABS brake hydraulic systems. 22. Road test vehicle to ensure proper operation of the base and antilock brake systems. RHD REMOVAL - RHD NOTE: Before proceeding, Refer to BRAKES WARNING. 1. Disconnect the negative (ground) cable from the battery and isolate cable. 2. Using a brake pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the HCU. 3. Raise vehicle. 4. Remove the routing clip attaching the ICU wiring harness to the ICU mounting bracket (Fig. 24). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 6113 CAUTION: Do not apply a 12 volt power source to any terminals of the HCU connector when disconnected. 5. Remove the 24-way connector (Fig. 24) from the CAB. The 24-way connector is removed from the CAB using the following procedure. Grasp the lock on the 24-way connector (Fig. 24) and pull it as far out as possible (Fig. 25). This will raise and unlock the 24-way connector from the socket on the CAB. CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the ports of HCU or entering the brake tubes. 6. Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent to clean the HCU. 7. Remove the brake tubes (6) from the inlet and outlet ports on the HCU. (Fig. 26). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 6114 8. Remove the 3 bolts (Fig. 27) attaching the ICU mounting bracket to the front suspension crossmember. 9. Remove ICU and the mounting bracket as a unit from the vehicle. 10. Remove the 3 bolts (Fig. 28) mounting the ICU to the mounting bracket. Separate the ICU from the mounting bracket. 11. For the procedure on separating and attaching the CAB to the HCU, refer to DISASSEMBLY. INSTALLATION - RHD 1. Install the ICU on the mounting bracket (Fig. 28). Install the 3 bolts (Fig. 28) attaching the ICU to the mounting bracket. Tighten the 3 mounting bolts to a torque of 11 Nm (97 inch lbs.). CAUTION: The ICU mounting bracket to front suspension cradle mounting bolts have a unique corrosion protection coating and a special aluminum washer. For this reason, only the original, or original equipment Mopar replacement bolts can be used to mount the ICU bracket to the front suspension crossmember. 2. Install the ICU and its mounting bracket as an assembly on the front suspension crossmember. Install the 3 bolts attaching the ICU bracket to the crossmember (Fig. 27). Tighten the 3 mounting bolts to a torque of 28 Nm (250 inch lbs.). CAUTION: Because of the flexible section in the primary and secondary brake tubes, and the brake tubes between the HCU and the proportioning valve, the brake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other or other vehicle components when installed. Also, after the brake tubes are installed on the HCU, ensure all spacer clips are reinstalled on the brake tubes. CAUTION: When installing the chassis brake tubes on the HCU valve block, they must be located correctly in the valve block to ensure proper ABS operation. Refer to (Fig. 26) for the correct chassis brake tube locations. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 6115 NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the ICU mounting bracket. 3. Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as shown in (Fig. 26). Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). NOTE: Before installing the 24-way connector in the CAB be sure the seal is properly installed in the connector. 4. Install the 24-way connector (Fig. 24) on the CAB using the following procedure. Position the 24-way connector in the socket of the CAB and carefully push it down as far as possible. When connector is fully seated by hand into the CAB socket, push in the connector lock (Fig. 25). This will pull the connector into the socket of the CAB and lock it in the installed position. NOTE: The CAB wiring harness must be clipped to the ICU mounting bracket. This will ensure the wiring harness is properly routed and does not contact the brake tubes or the body of the vehicle. 5. Clip the cab wiring harness (Fig. 24) to the ICU mounting bracket. 6. Install the routing clips (Fig. 32) on the brake tubes. 7. Lower the vehicle. 8. Connect negative cable back on negative post of the battery. 9. Bleed the base and ABS hydraulic systems. 10. Road test vehicle to ensure proper operation of the base and antilock brake systems. MK25E INTEGRATED CONTROL UNIT (ICU) - MK25E REMOVAL 1. Disconnect the negative (ground) cable from the battery and isolate it. 2. Remove the battery shield and battery. 3. Disconnect the vacuum hose connector at the tank built into the battery tray. 4. Remove the screw securing the engine coolant filler neck to the battery tray. 5. Remove the battery tray. 6. Using a brake pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This will prevent brake fluid from draining out of the master cylinder once the brake tubes are removed from the ICU. 7. Disconnect the wiring harness connector from the speed control servo. 8. Remove the speed control servo mounting nuts and move the servo out of the way. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 6116 9. Disconnect the 47-way connector from the antilock brake module (ABM) by depressing the tabs on each side of the connector cover (Fig. 34), then pulling outward and upward on the lower half of the cover until it locks into position pointing straight outward. The connector can then be pulled straight outward off the ABM (Fig. 35). CAUTION: Before removing the brake tubes from the ICU, the ICU must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the ports of ICU or entering the brake tubes. 10. Thoroughly clean all surfaces of the ICU and brake tube nuts. Use only a solvent such as Mopar Brake Parts Cleaner or equivalent to clean the ICU. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 6117 11. Remove the primary and secondary brake tubes from the inlet ports on the ICU (Fig. 36). 12. Remove the four chassis brake tubes from the outlet ports on the ICU (Fig. 37). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 6118 13. Remove the single mounting bolt (Fig. 38), then slide the mounting pins (on bottom of ICU) out of the grommets in the bracket. Remove the ICU. 14. If the ABM and HCU need to be separated, Refer to ABS/HYDRAULIC/MECHANICAL/ICU (INTEGRATED CONTROL UNIT). INSTALLATION 1. Place the ICU in its bracket below the master cylinder by first inserting the mounting pins on the bottom of the ICU into the grommets mounted in the bracket, then install the single mounting bolt on the side (Fig. 38). Tighten the mounting bolt to 11 Nm (97 inch lbs.) torque. 2. Install the four chassis brake tubes into their correct port locations on the ICU as shown (Fig. 37). Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). CAUTION: Because of the flexible section in the primary and secondary brake tubes, the brake tubes must be held in proper orientation when tightened and torqued. These tubes must not contact each other or other vehicle components when installed. Also, after the brake tubes are installed on the ICU, ensure all spacer clips are reinstalled on the brake tubes. 3. Install the primary and secondary brake tubes into their correct port locations on the ICU (Fig. 36). Tighten the tube nuts to a torque of 17 Nm (145 inch lbs.). 4. Install any routing clips on the brake tubes. 5. With connector cover completely open (Fig. 35), install 47-way wiring connector into socket of the ABM and close cover, locking connector in place. 6. Install the speed control servo with its mounting nuts. 7. Connect the wiring harness to the speed control servo. 8. Install the battery tray. 9. Install the screw securing the coolant filler neck to the battery tray. 10. Reconnect the vacuum hose connector at the tank built into the battery tray. 11. Install the battery and battery shield. 12. Remove the brake pedal holder. 13. Connect the negative cable on the battery negative post. 14. Hook up a scan tool to initialize ABM and check for any faults. 15. Fill master cylinder with clean, fresh Mopar Brake Fluid or equivalent, then bleed base brakes and ABS. 16. Road test vehicle to ensure proper operation of brakes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 6119 Hydraulic Control Assembly - Antilock Brakes: Service and Repair ICU - Disassembly and Assembly MK20E DISASSEMBLY - ICU 1. Remove the ICU from the vehicle. 2. Disconnect the pump/motor wiring harness from the CAB (Fig. 29). 3. Remove the 4 bolts (Fig. 30) attaching the CAB to the HCU. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 6120 4. Remove the CAB from the HCU (Fig. 31). ASSEMBLY - ICU 1. Install the CAB (Fig. 31) on the HCU. 2. Install the 4 bolts mounting the CAB (Fig. 30) to the HCU. Tighten the CAB mounting bolts to a torque of 2 Nm (17 inch lbs.). 3. Plug the pump/motor wiring harness into the CAB. 4. Install the ICU in the vehicle and bleed the base and ABS hydraulic systems. MK25E INTEGRATED CONTROL UNIT (ICU) - MK25E DISASSEMBLY 1. If not equipped with traction control, remove the three screws attaching the ABM to the HCU (Fig. 39). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 6121 2. If equipped with traction control, remove the four screws attaching the ABM to the HCU (Fig. 40). 3. Separate the ABM from the HCU (Fig. 41). ASSEMBLY 1. Clean any debris off the mating surfaces of the HCU and ABM. CAUTION: When installing new O-rings or solenoid valve stem seals, do not use any type of lubricant. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > ICU - Removal and Installation > Page 6122 2. If the seals on the components are not new, they must be replaced. Each of the solenoid valve stem seals must be replaced (Fig. 42); do not reuse solenoid valve stem seals. The pump/motor connector O-ring should also be replaced if not new (Fig. 43). 3. Align components and install the ABM on the HCU (Fig. 41). 4. If not equipped with traction control, install the three screws attaching the ABM to the HCU (Fig. 39). Tighten the mounting screws to 2 Nm (17 inch lbs.) torque. 5. If equipped with traction control, install the four screws attaching the ABM to the HCU (Fig. 40). Tighten the mounting screws to 2 Nm (17 inch lbs.) torque. 6. Install the ICU in the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block > Component Information > Description and Operation Hydraulic System Junction Block: Description and Operation JUNCTION BLOCK DESCRIPTION - NON-ABS JUNCTION BLOCK A junction block is used on vehicles that are not equipped with antilock brakes (ABS). The junction block mounts in the same location as the integrated control unit (ICU) does on vehicles equipped with ABS. This allows for use of the same brake tube configuration on all vehicles. The junction block is located on the driver's side of the front suspension cradle/crossmember below the master cylinder (Fig. 44). It has six threaded ports to which the brake tubes connect. Two are for the primary and secondary brake tubes coming from the master cylinder. The remaining four are for the chassis brake tubes going to each brake assembly. OPERATION - NON-ABS JUNCTION BLOCK The junction block distributes the brake fluid coming from the master cylinder primary and secondary ports to the four chassis brake tubes leading to the brakes at each wheel. Since the junction block mounts in the same location as the ABS integrated control unit (ICU) it allows for the common use of brake tubes going to the brakes whether the vehicle is equipped with or without ABS. NOTE: Although the brake tubes coming from the master cylinder to the junction block or ABS ICU may appear to be the same, they are not. They are unique to each brake system application. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block > Component Information > Description and Operation > Page 6126 Hydraulic System Junction Block: Service and Repair JUNCTION BLOCK REMOVAL - NON-ABS JUNCTION BLOCK 1. Using a brake pedal depressor, move and lock the brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of the master cylinder when the brake tubes are removed from the junction block. 2. Disconnect the battery negative cable. 3. If the vehicle is equipped with speed control, perform the following: a. Disconnect the battery positive cable. b. Remove the battery. c. Disconnect the vacuum hose connector at the tank built into the battery tray. d. Remove the screw securing the coolant filler neck to the battery tray. e. Remove the battery tray. f. Remove the fasteners and move the speed control servo off to the side, out of the way. CAUTION: Before removing the brake tubes from the junction block, the junction block and the brake tubes must be thoroughly cleaned. This is required to prevent contamination from entering the brake hydraulic system. 4. Remove the four chassis brake tubes from the top of the junction block (Fig. 44). 5. Remove the primary and secondary brake tubes from the top of the junction block. 6. Remove the bolts attaching the junction block mounting bracket to the front suspension crossmember (Fig. 44), then remove the junction block. INSTALLATION - NON-ABS JUNCTION BLOCK 1. Install the junction block and mounting bracket on the front suspension crossmember (Fig. 44). Install the mounting bolts and tighten to a torque of 28 Nm (250 inch lbs.). 2. Install the primary and secondary brake tubes from the master cylinder in their ports. Tighten tube nuts to a torque of 17 Nm (145 inch lbs.). Take care not to twist tubes when tightening tube nuts. They must be properly positioned to allow free movement with rubber isolated suspension crossmember. 3. Install the four chassis brake tubes into the outlet ports of the junction block. Tighten all 6 tube nuts to a torque of 17 Nm (145 inch lbs.). 4. If the vehicle is equipped with speed control, perform the following: a. Install the speed control servo with its mounting nuts. b. Connect the wiring harness to the speed control servo. c. Install the battery tray. d. Install the screw securing the coolant filler neck to the battery tray. e. Reconnect the vacuum hose connector at the tank built into the battery tray. f. Install the battery. g. Install the battery shield. 5. Remove the brake pedal holder. 6. Connect negative cable back on negative post of the battery. 7. Bleed the brake system thoroughly to ensure that all air has been expelled from the hydraulic system. 8. Road test the vehicle to verify proper operation of the brake system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation Brake Master Cylinder: Description and Operation MASTER CYLINDER DESCRIPTION The master cylinder is located on the power brake booster in the engine compartment on the driver's side (Fig. 45). This vehicle uses 3 different master cylinders. Master cylinder usage depends on what type of brake system the vehicle is equipped with. CAUTION: Master cylinders are not interchangeable between systems. Performance and stopping distance issues will result if the incorrect master cylinder is installed on the vehicle. For information on master cylinder application, bore and type, view the following table: CAUTION: When replacing a master cylinder, be sure to use the correct master cylinder for the type of brake system the vehicle is equipped with. The body of the master cylinder is an anodized aluminum casting. It has a machined bore to accept the master cylinder pistons and threaded ports with seats for the hydraulic brake line connections. The brake fluid reservoir is mounted on the top of the master cylinder. It is made of a see-through polypropylene type plastic for easy fluid level viewing. A brake fluid level switch is attached to the brake fluid reservoir. The master cylinder is not a repairable component and must be replaced if diagnosed to be functioning improperly. The brake fluid reservoir and brake fluid level switch can be replaced separately. CAUTION: Do not hone the bore of the cylinder as this will remove the anodized surface from the bore. DESCRIPTION - RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Page 6130 The master cylinder used on right hand drive (RHD) vehicles functions similarly to that used on left hand drive (LHD) vehicles. The RHD master cylinder, as well as the RHD power brake booster, is located in the same area, but lower in the engine compartment than LHD models (Fig. 46). For that reason an extension manifold is placed between the fluid reservoir and master cylinder housing allowing the fluid reservoir to be positioned in the same location as on LHD models. OPERATION When the brake pedal is depressed, the master cylinder primary and secondary pistons apply brake pressure through the chassis tubes to the brakes at each tire and wheel assembly. The master cylinder primary outlet port supplies hydraulic pressure to the right front and left rear brakes. The secondary outlet port supplies hydraulic pressure to the left front and right rear brakes. ABS SWITCHES/SENSORS Master Cylinder: The master cylinder is a standard tandem compensating port design for ABS and non ABS systems. Traction control vehicles use a dual center port master cylinder. For proper traction control operation the standard master cylinder must not be used. A fluid level switch is located in the master cylinder fluid reservoir. The switch closes when a low fluid level is detected. The fluid level switch turns on the brake warning indicator by grounding the indicator circuit. This switch does not disable the ABS system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding Brake Master Cylinder: Service and Repair Master Cylinder Bleeding STANDARD PROCEDURE - MASTER CYLINDER BLEEDING CAUTION: When clamping master cylinder in vise, only clamp master cylinder by its mounting flange. Do not clamp master cylinder piston rod, reservoir, seal or body. 1. Clamp master cylinder in a vise. NOTE: Use correct bleeder tubes when bleeding master cylinder. Master cylinder outlet ports vary in size and type depending on whether master cylinder is for a vehicle equipped with ABS or not. ABS equipped master cylinders require the additional use of ISO style flare adapters supplied in Special Tool Package 8822 to be used in conjunction with Bleeder Tubes, Special Tool Package 8358. 2. Attach special tools for bleeding master cylinder in the following fashion: a. For non-ABS control equipped master cylinders, thread a Bleeder Tube, Special Tool 8358-1, into each outlet port. Tighten each tube to 17 Nm (145 inch lbs.) torque. Flex bleeder tubes and place open ends into mouth of fluid reservoir as far down as possible (Fig. 47). b. For ABS equipped master cylinders, thread one Adapter, Special Tool 8822-2, in each outlet port. Tighten Adapters to 17 Nm (145 inch lbs.) torque. Next, thread a Bleeder Tube, Special Tool 8358-1, into each Adapter. Tighten each tube to 17 Nm (145 inch lbs.) torque. Flex bleeder tubes and place open ends into mouth of fluid reservoir as far down as possible (Fig. 47). NOTE: Make sure open ends of bleeder tubes stay below surface of brake fluid once reservoir is filled to proper level. 3. Fill brake fluid reservoir with Mopar brake fluid or equivalent conforming to DOT 3 (DOT 4 and DOT 4+ are acceptable) specifications. Make sure fluid level is above tips of bleeder tubes in reservoir to ensure no air is ingested during bleeding. 4. Using a wooden dowel as a pushrod (Fig. 47), slowly depress master cylinder pistons, then release pressure, allowing pistons to return to released position. Repeat several times until all air bubbles are expelled. Make sure fluid level stays above tips of bleeder tubes in reservoir while bleeding. 5. Remove bleeder tubes from master cylinder outlet ports, then plug outlet ports and install fill cap on reservoir. 6. Remove master cylinder from vise. 7. Install master cylinder on vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 6133 Brake Master Cylinder: Service and Repair Brake Master Cylinder - LHD MASTER CYLINDER REMOVAL - LHD CAUTION: Vacuum in the power brake booster must be pumped down (removed) before removing master cylinder from power brake booster. This is necessary to prevent the power brake booster from sucking in any contamination as the master cylinder is removed. This can be done simply by pumping the brake pedal, with the vehicle's engine not running, until a firm feeling brake pedal is achieved. 1. With engine not running, pump brake pedal until a firm pedal is achieved (4-5 strokes). 2. Disconnect negative battery terminal. 3. Disconnect positive battery terminal. 4. Remove battery shield. 5. Remove nut and clamp securing battery to tray, remove battery. 6. Thoroughly clean all surfaces of the brake fluid reservoir and master cylinder. Use only solvent such as Mopar Brake Parts Cleaner or equivalent. 7. Remove wiring harness connector from brake fluid level switch in master cylinder brake fluid reservoir (Fig. 48). 8. Disconnect primary and secondary brake tubes from master cylinder housing (Fig. 48). Install sealing plugs in the now open brake tube outlet ports. CAUTION: Before removing the master cylinder from the power brake vacuum booster, the master cylinder and vacuum booster must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the power brake vacuum booster. 9. Clean area where master cylinder assembly attaches to power brake booster. Use only a solvent such as Mopar Brake Parts Cleaner or equivalent. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 6134 10. Remove two nuts attaching master cylinder to power brake booster (Fig. 49). 11. Slide master cylinder straight out of power brake booster. CAUTION: A seal on the rear of the master cylinder is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal on the master cylinder MUST be replaced whenever the master cylinder is removed from the power brake vacuum booster. 12. Remove vacuum seal located on the mounting flange of the master cylinder. The vacuum seal is removed from master cylinder by carefully pulling it off the rear of master cylinder. Do not attempt to pry the seal off the master cylinder by inserting a sharp tool between seal and master cylinder casting. INSTALLATION - LHD CAUTION: Different types of master cylinders are used on this vehicle depending on brake options. If a new master cylinder is being installed, be sure it is the correct master cylinder for the type of brake system the vehicle is equipped with. CAUTION: When replacing the master cylinder on a vehicle, a NEW vacuum seal MUST be installed on the master cylinder. 1. Install a NEW vacuum seal on master cylinder making sure seal fits squarely in groove of master cylinder casting. 2. Position master cylinder on studs of power brake booster, aligning booster push rod with master cylinder piston. 3. Install the two master cylinder mounting nuts (Fig. 49). Tighten both mounting nuts to a torque of 25 Nm (225 inch lbs.). CAUTION: When tightening the primary and secondary brake tube nuts at master cylinder, be sure brake tubes do not contact any other components within the vehicle and that there is slack in the flexible sections of the tubes. This is required due to the movement between the ABS ICU and the master cylinder while the vehicle is in motion. 4. Connect primary and secondary brake tubes to master cylinder primary and secondary ports (Fig. 48). Brake tubes must be held securely when tightened to control orientation of flex section. Tighten tube nuts to a torque of 17 Nm (145 inch lbs.). 5. Install wiring harness connector to brake fluid level switch mounted in brake fluid reservoir (Fig. 48). 6. Install battery, clamp and nut. 7. Install battery shield. 8. Connect positive battery terminal. 9. Connect negative battery terminal. 10. Fill master cylinder with clean, fresh Mopar Brake Fluid or equivalent. 11. Road test vehicle to ensure proper operation of brakes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 6135 Brake Master Cylinder: Service and Repair Brake Master Cylinder - RHD MASTER CYLINDER REMOVAL - RHD CAUTION: Vacuum in the power brake booster must be pumped down (removed) before removing master cylinder from power brake booster. This is necessary to prevent the power brake booster from sucking in any contamination as the master cylinder is removed. This can be done simply by pumping the brake pedal, with the vehicle's engine not running, until a firm feeling brake pedal is achieved. 1. With engine not running, pump brake pedal until a firm pedal is achieved (4 or 5 strokes). 2. Disconnect negative battery terminal. 3. Disconnect positive battery terminal. 4. Remove battery shield. 5. Remove nut and clamp securing battery to tray, remove battery. 6. Thoroughly clean all surfaces of the brake fluid reservoir and master cylinder. Use only solvent such as Mopar Brake Parts Cleaner or equivalent. 7. Remove wiring harness connector from brake fluid level switch in master cylinder brake fluid reservoir (Fig. 46). 8. Disconnect primary and secondary brake tubes from master cylinder housing (Fig. 50). Install sealing plugs in the now open brake tube outlet ports. CAUTION: Before removing the master cylinder from the power brake vacuum booster, the master cylinder and vacuum booster must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the power brake vacuum booster. 9. Clean area where master cylinder assembly attaches to power brake booster. Use only a solvent such as Mopar Brake Parts Cleaner or equivalent. 10. Remove two nuts attaching master cylinder to power brake booster (Fig. 50). 11. Slide master cylinder straight out of power brake booster. CAUTION: A seal on the rear of the master cylinder is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal on the master cylinder MUST be replaced whenever the master cylinder is removed from the power brake vacuum booster. 12. Remove vacuum seal located on the mounting flange of the master cylinder. The vacuum seal is removed from master cylinder by carefully pulling it off the rear of master cylinder. Do not attempt to pry the seal off the master cylinder by inserting a sharp tool between seal and master cylinder casting. INSTALLATION - RHD CAUTION: Different types of master cylinders are used on this vehicle depending on brake options. If a new master cylinder is being installed, be sure it is the correct master cylinder for the type of brake system the vehicle is equipped with. CAUTION: When replacing the master cylinder on a vehicle, a NEW vacuum seal MUST be installed on the master cylinder. 1. Install a NEW vacuum seal on master cylinder making sure seal fits squarely in groove of master cylinder casting. 2. Position master cylinder on studs of power brake booster, aligning booster push rod with master cylinder piston. 3. Install the two master cylinder mounting nuts (Fig. 50). Tighten both mounting nuts to a torque of 25 Nm (225 inch lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 6136 CAUTION: When tightening the primary and secondary brake tube nuts at master cylinder, be sure brake tubes do not contact any other components within the vehicle and that there is slack in the flexible sections of the tubes. This is required due to the movement between the ABS ICU and the master cylinder while the vehicle is in motion. 4. Connect primary and secondary brake tubes to master cylinder primary and secondary ports (Fig. 50). Brake tubes must be held securely when tightened to control orientation of flex section. Tighten tube nuts to a torque of 17 Nm (145 inch lbs.). 5. Install wiring harness connector to brake fluid level switch mounted in brake fluid reservoir (Fig. 46). 6. Install battery, clamp and nut. 7. Install battery shield. 8. Connect positive battery terminal. 9. Connect negative battery terminal. 10. Fill master cylinder with clean, fresh Mopar Brake Fluid or equivalent. 11. Road test vehicle to ensure proper operation of brakes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Bleeding > Page 6137 Brake Master Cylinder: Service and Repair Brake Master Cylinder Fluid Reservoir DISASSEMBLY - MASTER CYLINDER (FLUID RESERVOIR) 1. Clean master cylinder housing and brake fluid reservoir. Use only a solvent such as Mopar Brake Parts Cleaner or an equivalent. 2. Remove brake fluid reservoir cap. Using a syringe or equivalent type tool empty as much brake fluid as possible from the reservoir. CAUTION: When removing fluid reservoir from the master cylinder, do not pry off using any type of tool. This can damage the fluid reservoir or master cylinder housing. 3. Remove the master cylinder assembly from the power brake vacuum booster. 4. Mount the master cylinder in a vise using the master cylinder mounting flange. 5. Using correct size pin punch, remove the two retaining pins between the fluid reservoir and master cylinder housing (Fig. 51). 6. Rock the brake fluid reservoir from side to side while pulling up to remove it from the seal grommets in master cylinder housing. 7. Remove the two master cylinder housing to brake fluid reservoir seal grommets (Fig. 52). ASSEMBLY - MASTER CYLINDER (FLUID RESERVOIR) 1. Install new master cylinder housing to brake fluid reservoir sealing grommets in master cylinder housing (Fig. 52). 2. Lubricate reservoir mounting area with fresh clean brake fluid. Place reservoir in position over sealing grommets. Seat reservoir into sealing grommets using a rocking motion while firmly pressing down on fluid reservoir. 3. Be sure fluid reservoir is positioned properly on master cylinder. Bottom of fluid reservoir is to be touching the top of both sealing grommets when properly installed on master cylinder housing. 4. Install the two fluid reservoir to master cylinder retaining pins (Fig. 51). 5. Install the master cylinder assembly on the power brake booster. 6. Fill fluid reservoir to its proper level as indicated on the side of the fluid reservoir. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair Wheel Cylinder: Service and Repair WHEEL CYLINDERS REMOVAL 1. Using a brake pedal depressor, move and secure brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out of master cylinder when brake tube is remove from wheel cylinder. 2. Raise vehicle. 3. Remove wheel and tire assembly. 4. Disconnect brake tube from rear of wheel cylinder. Cap open ends 5. Remove brake drum. 6. Remove brake shoes from brake support plate (Discard if contaminated). 7. Remove the 2 bolts attaching the wheel cylinder to the brake support plate. 8. Remove the wheel cylinder from the brake support plate. INSPECTION With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel cylinders should be completely cleaned, inspected and new parts installed. If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake shoes must be replaced. INSTALLATION 1. Apply sealant such as Mopar Gasket-In-A-Tube or equivalent around the wheel cylinder opening in the brake support plate. 2. Install wheel cylinder onto brake support. Install and tighten the wheel cylinder to brake support plate attaching bolts to 8 Nm (75 inch lbs.) torque. 3. Install brake tube into wheel cylinder. Tighten tube nut to a torque of 17 Nm (145 inch lbs.) torque. 4. Install the rear brake shoes on the brake support plate. 5. Install brake drum. 6. Install wheel and tire. Install and tighten wheel lug nuts to 135 Nm (100 ft. lbs.). 7. Adjust drum brake shoes. 8. Remove brake pedal depressor tool. 9. Bleed the brake system as necessary. 10. Lower vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front Parking Brake Cable: Service and Repair Front CABLE - PARKING BRAKE FRONT REMOVAL 1. Raise and support the vehicle. 2. Manually release the automatic self-adjusting mechanism tension of the parking brake lever (pedal) assembly. 3. Remove the intermediate and left rear park brake cable from the park brake cable equalizer (Fig. 100). 4. Remove the front park cable housing retainer from body outrigger bracket (Fig. 101). Cable is removable by sliding a 14 mm box wrench over cable retainer and compressing the three retaining fingers. Alternate method is to use an aircraft type hose clamp and screwdriver. 5. Lower vehicle. 6. Remove the left front door sill molding. 7. Remove the left front kick panel for access to the park brake cable and park brake pedal assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 6146 8. Lift floor mat for access to park brake cable and floor pan. Pull the seal and the park brake cable (Fig. 102) out of the floor pan of vehicle. 9. Pull parking brake cable strand end forward and disconnect button from clevis. Tap cable housing end fitting out of pedal assembly bracket. 10. Remove cable retainer from the parking brake lever (pedal) assembly bracket. 11. Pull front parking brake cable assembly out of vehicle through hole in floor pan. REMOVAL - FOLD-IN-FLOOR SEATING 1. Release the parking brake. 2. Raise and support the vehicle. 3. Manually release the automatic self-adjusting mechanism tension of the parking brake lever (pedal) assembly. 4. Remove the front cable from the equalizer (Fig. 103). 5. Remove the locking pliers from the cable that were installed during Step 3. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 6147 6. Remove the front cable from the routing clips fastened to the underbody of the vehicle (Fig. 104). 7. Place a 13 mm 12-point box wrench over the cable retainer at the intermediate bracket as shown to collapse the retainer fingers (Fig. 105). 8. Pull the cable out of the intermediate bracket. 9. Lower the vehicle. 10. Remove the left front door sill molding. 11. Remove the left front kick panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 6148 12. Pull the parking brake cable strand forward and disconnect the end button from the lever (pedal) assembly mechanism reel (Fig. 106). 13. Slide the cable out of the lever bracket. 14. Lift back the carpet and pull the cable seal loose from the floor pan (Fig. 102). 15. Pull the front parking brake cable assembly out of the vehicle through the hole in the floor pan. REMOVAL - EXPORT Refer to BASE/PARKING BRAKE/LEVER - REMOVAL INSTALLATION 1. Pass front parking brake cable assembly through hole in floor pan from the inside of the vehicle. 2. Pass cable strand button through the hole in the lever (pedal) assembly bracket. 3. Install cable retainer onto the park brake cable and then install cable retainer into pedal assembly bracket. 4. Install the end of the park brake cable into the retainer previously installed into the park brake pedal bracket. 5. Install cable strand button into the clevis on the park brake pedal mechanism. 6. Install the front park brake cable floor pan seal into hole in floor pan. Seal is to be installed so the flange on the seal is flush with the floor pan (Fig. 102). Fold carpeting back down on floor. 7. Raise vehicle. 8. Insert brake cable and housing into body outrigger bracket making certain that housing retainer fingers lock the housing firmly into place (Fig. 101). 9. Manually reset the automatic self-adjusting mechanism tension of the parking brake lever (pedal) assembly. 10. Assemble the park brake cables onto the park brake cable equalizer (Fig. 100). 11. Lower vehicle and apply the park brake pedal 1 time. This will seat the parking brake cables. INSTALLATION - FOLD-IN-FLOOR SEATING 1. Pass most of the front parking brake cable assembly down through hole in the floor pan from inside the vehicle. 2. Pass the lever-end cable strand button through the hole in the lever (pedal) assembly bracket. 3. Install the end of the cable housing into the retainer installed into the park brake pedal bracket. 4. Install cable strand button into the reel on the parking brake lever mechanism (Fig. 106). 5. Install the front parking brake cable floor pan seal into the hole in the floor pan. The seal flange should be flush with the floor pan (Fig. 102). 6. Reposition the carpeting back down on the floor. 7. Install the left front kick panel. 8. Install the left front door sill molding. 9. Raise and support the vehicle. 10. Pass the end of the cable through the hole in the end of the intermediate bracket (Fig. 104). Press the cable housing retainer through the hole until the fingers on the retainer lock it into place. 11. Attach the front cable to the routing clips fastened to the underbody of the vehicle (Fig. 104). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 6149 12. Clamp an appropriate pair of locking pliers on the front cable strand approximately 25 mm (1 inch) forward of the button (Fig. 107). 13. Pull straight back on the front cable button (and pliers) and properly attach the equalizer to all three parking brake cables (Fig. 103). 14. Remove the locking pliers from the front parking brake cable and allow the automatic self-adjusting mechanism in the lever to take up any slack. 15. Lower the vehicle. 16. Apply and release park brake pedal 1 time. This will seat the parking brake cables. INSTALLATION - EXPORT Refer to BASE/PARKING BRAKE/LEVER - INSTALLATION. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 6150 Parking Brake Cable: Service and Repair Intermediate CABLE - PARKING BRAKE INTERMEDIATE REMOVAL 1. Raise and support the vehicle. 2. Manually lock out the automatic self-adjusting mechanism tension of the parking brake lever (pedal) assembly. Once the cable is released from the equalizer, do not remove the locking pliers until reinstallation of the cable is complete. 3. Remove the intermediate parking brake cable from the parking brake cable equalizer (Fig. 108). 4. Remove the locking nut securing the intermediate cable housing to the side bracket on the frame rail (Fig. 108). 5. Remove the intermediate parking brake cable from the cable connector attaching it to the right rear parking brake cable (Fig. 109). Remove the locking nut securing the intermediate cable housing to the side bracket on the frame rail (Fig. 109). 6. If the vehicle is a short-wheel-base model, it will be necessary to loosen and lower the fuel tank far enough to remove the intermediate parking brake cable. 7. Remove the intermediate parking brake cable from the side brackets and vehicle. INSTALLATION 1. Install the ends of the park brake cables through the frame rails and into the side brackets. 2. Install the locking nuts at each end of the cable and securely tighten (Fig. 108) (Fig. 109). 3. If the vehicle is a short-wheel-base model, it will be necessary to reinstall the fuel tank to its normal mounting position. 4. Install the intermediate parking brake cable on the cable connector at the right rear parking brake cable (Fig. 109). 5. Install the intermediate park brake cable on the cable equalizer (Fig. 108). 6. Remove the locking pliers from the front park brake cable. This will activate the automatic adjuster and correctly adjust the parking brake cables. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 6151 7. Install and position the foam collar on the parking brake cable to prevent it from rattling against the vehicle's floor. 8. Lower the vehicle and apply the park brake pedal 1 time, this will seat the park brake cables. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 6152 Parking Brake Cable: Service and Repair Rear CABLE PARKING BRAKE REAR REMOVAL REMOVAL - RIGHT REAR 1. Raise and support the vehicle. 2. Remove rear tire and wheel assembly. 3. Remove rear brake drum from the rear wheel of the vehicle requiring service to the rear park brake cable. 4. Create slack in the rear parking brake cables by locking out the automatic adjuster as described here. Grasp an exposed section of front parking brake cable near the equalizer and pull down on it. At this time install a pair of locking pliers on the cable just rearward of the second body outrigger bracket (Fig. 110). 5. Disconnect the right rear parking brake cable from the connector on the intermediate cable (Fig. 111). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 6153 6. To remove the right parking brake cable housing from the body bracket, slide a 14 mm box end wrench over the end of cable retainer to compress the retaining fingers (Fig. 112). The alternate method using an aircraft type hose clamp will not work on the right side of the vehicle. 7. Remove the brake shoes from the brake support plate. 8. Disconnect parking brake cable from parking brake actuator lever. 9. Remove the parking brake cable housing retainer from the brake support plate using a 14mm wrench to compress the retaining fingers (Fig. 113). Remove the cable. REMOVAL - LEFT REAR 1. Raise and support the vehicle. 2. Remove rear tire and wheel assembly. 3. Remove rear brake drum from the rear wheel of the vehicle requiring service to the rear park brake cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 6154 4. Create slack in rear park brake cables by locking out the automatic adjuster as described here. Grasp an exposed section of front park brake cable near the equalizer and pull down on it. Then install a pair of locking pliers on the cable just rearward of the second body outrigger bracket (Fig. 114). 5. Disconnect the left rear parking brake cable from the parking brake cable equalizer (Fig. 115). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 6155 6. To remove parking brake cable housing from the body bracket, slide a 14 mm box end wrench over retainer end compressing the three fingers (Fig. 116). Alternate method is to use an aircraft type hose clamp. 7. Remove the brake shoes from the brake support plate. 8. Disconnect parking brake cable from parking brake actuator lever. 9. Remove the parking brake cable housing retainer from the brake support plate using a 14mm wrench to compress the retaining fingers (Fig. 117). REMOVAL - FOLD-IN-FLOOR SEATING 1. Release the parking brake. 2. Raise and support the vehicle. 3. Manually release the automatic self-adjusting mechanism tension of the parking brake lever (pedal) assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 6156 4. Remove the equalizer (Fig. 118). 5. Remove the cable from the routing bracket fastened to the underbody of the vehicle (Fig. 119). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 6157 6. If the right rear cable is being serviced, remove the screws fastening the cable routing clamps to the rear axle (Fig. 120). 7. Remove the screw fastening the cable to the rear brake adapter (Fig. 121). 8. Unhook the cable eyelet from the shoe lever (Fig. 121). 9. Slide the cable out of the brake adapter. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 6158 10. Place a 13 mm 12-point box wrench over the cable retainer at the intermediate bracket as shown to collapse the retainer fingers (Fig. 122). 11. Pull the cable out of the intermediate bracket and remove it from the vehicle (Fig. 123). INSTALLATION INSTALLATION - RIGHT REAR 1. Install the rear parking brake cable in the brake support plate. Insert cable housing retainer into brake support plate making certain that cable housing retainer fingers lock the housing and retainer firmly into place. 2. Attach the parking brake cable onto the parking brake actuator lever. 3. Install the brake shoes on the rear brake support plate. 4. Insert cable housing retainer into body outrigger bracket making certain that cable housing retainer fingers lock the housing firmly into place. 5. Connect the right rear parking brake cable to the connector on the intermediate parking brake cable (Fig. 111). 6. Install the brake drum, then the wheel and tire assembly. 7. Remove the locking pliers from the front park brake cable. This will automatically adjust the park brake cables. 8. Lower the vehicle. 9. Apply and release park brake pedal 1 time. This will seat the park brake cables. INSTALLATION - LEFT REAR 1. Install the rear parking brake cable in the brake support plate. Insert cable housing retainer into brake support plate making certain that cable Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Front > Page 6159 housing retainer fingers lock the housing and retainer firmly into place. 2. Attach the parking brake cable onto the park brake actuator lever. 3. Install the brake shoes on the rear brake support plate. 4. Insert cable housing retainer into body outrigger bracket making certain that cable housing retainer fingers lock the housing firmly into place. 5. Connect rear parking brake cable to the equalizer bracket (Fig. 115). 6. Install brake drum, and wheel and tire assembly. 7. Remove the locking pliers from the front park brake cable. This will automatically adjust the park brake cables. 8. Apply and release park brake pedal 1 time. This will seat the park brake cables. INSTALLATION - FOLD-IN-FLOOR SEATING 1. Pass the leading end of the rear parking brake cable through the hole in the end of the intermediate bracket (Fig. 123). Press the cable housing retainer through the hole until the fingers on the retainer lock it into place. 2. Route the cable back toward the brake assembly placing it in the routing clip fastened to the underbody of the vehicle (Fig. 119). Make sure to stay to the inside of the left stabilizer bar link while routing either cable. 3. If the right rear cable is being serviced, install screws, attaching the cable routing clamps to the rear axle (Fig. 120). 4. Pass the cable through the hole in the brake adapter and hook the cable eyelet to the shoe lever (Fig. 121). 5. Install the screw fastening the cable to the rear brake adapter (Fig. 121). 6. Pull straight back on the front cable button (and pliers) and properly attach the equalizer to all three parking brake cables (Fig. 118). 7. Remove the locking pliers from the front parking brake cable and allow the automatic self-adjusting mechanism in the lever to take up any slack. 8. Lower the vehicle. 9. Apply and release park brake pedal 1 time. This will seat the parking brake cables. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair Parking Brake Lever: Service and Repair LEVER - PARKING BRAKE REMOVAL 1. Manually release the automatic self-adjusting mechanism tension of the parking brake lever (pedal) assembly. 2. Disconnect negative (ground) cable from the battery and isolate cable from battery terminal. 3. Remove sill scuff plate from left door sill. 4. Remove the left side kick panel. 5. Remove the steering column cover from the lower instrument panel. 6. Remove the reinforcement from the lower instrument panel. 7. Remove the three bolts mounting the wiring junction block to the instrument panel. NOTE: When removing the lower mounting bolt, push the park brake pedal down 5 clicks to access the lower mounting bolt. 8. Remove the lower bolt mounting the parking brake lever (pedal) to the body (Fig. 124). 9. Remove the forward nut mounting the parking brake lever to the body (Fig. 124). 10. Remove the upper bolt mounting the parking brake lever to the body (Fig. 124). 11. Pull downward on front parking brake cable while rotating lever assembly out from behind junction block. 12. Remove the release link from the parking brake lever assembly. 13. Disconnect the wiring connector from the indicator lamp ground switch (Fig. 124) (Fig. 125). 14. Remove front parking brake cable strand button from the lever mechanism reel (Fig. 125). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Service and Repair > Page 6163 15. Remove the parking brake lever assembly from the cable. INSTALLATION 1. Install the parking brake cable end housing into the mounting hole in the parking brake lever (pedal) assembly. 2. Install cable strand button into the reel on the parking brake pedal mechanism (Fig. 125). 3. Connect the wiring connector to the indicator lamp ground switch (Fig. 125). 4. Install the release link on the release mechanism of the parking brake lever. 5. Position the lever into its installed position on the body of the vehicle. 6. Loosely install the top bolt mounting the lever to the body (Fig. 124). 7. Loosely install the forward nut mounting the lever to the body (Fig. 124). 8. Loosely install the lower bolt mounting the lever to the body (Fig. 124). 9. Tighten lever mounting bolts and nut to 28 Nm (250 inch lbs.). 10. Verify that the parking brake lever is in the fully released (full up) position. 11. Raise and support the vehicle. 12. Install the front parking brake cable on the cable equalizer. If a new lever assembly is NOT being installed, perform PARKING BRAKE AUTOMATIC ADJUSTER TENSION RESET as necessary. NOTE: If the original lever assembly is being used, the lever mechanism auto adjuster spring tension will need to be reset. 13. Lower vehicle. 14. If a new lever is being installed, remove the lockout pin from the automatic adjuster on the parking brake lever mechanism allowing the automatic self-adjusting mechanism in the lever to take up any slack (Fig. 125). 15. Install the electrical junction block on the instrument panel. 16. Install the reinforcement on the lower instrument panel. 17. Install the steering column lower cover on the lower instrument panel. 18. Install the left side kick panel. 19. Install the sill scuff plate on the lower sill of the left door. 20. Install the negative (ground) cable on the battery. 21. Cycle the parking brake pedal one time. This will seat the park brake cables and allow the automatic self-adjuster to properly tension the parking brake cables. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments Parking Brake Shoe: Adjustments ADJUSTMENT - PARKING BRAKE SHOES CAUTION: Before adjusting the park brake shoes be sure that the park brake pedal is in the fully released position. If park brake pedal is not in the fully released position, the park brake shoes can not be accurately adjusted. 1. Raise vehicle. 2. Remove tire and wheel. 3. Remove disc brake caliper from caliper adapter (Fig. 150). 4. Remove rotor from hub/bearing. NOTE: When measuring the brake drum diameter, the diameter should be measured in the center of the area in which the park brake shoes contact the surface of the brake drum. 5. Using Brake Shoe Gauge, Special Tool C-3919, or equivalent, accurately measure the inside diameter of the park brake drum portion of the rotor (Fig. 151). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 6167 6. Using a ruler that reads in 64th of an inch, accurately read the measurement of the inside diameter of the park brake drum from the special tool (Fig. 152). 7. Reduce the inside diameter measurement of the brake drum that was taken using Special Tool C-3919 by 1/64 of an inch. Reset Gauge, Brake Shoe, Special Tool C-3919 or the equivalent used, so that the outside measurement jaws are set to the reduced measurement (Fig. 153). 8. Place Gauge, Brake Shoe, Special Tool C-3919, or equivalent over the park brake shoes. The special tool must be located diagonally across at the top of one shoe and bottom of opposite shoe (widest point) of the park brake shoes. 9. Using the star wheel adjuster, adjust the park brake shoes until the lining on the park brake shoes just touches the jaws on the special tool. 10. Repeat step 8 above and measure shoes in both directions. 11. Install brake rotor on hub and bearing. 12. Rotate rotor to verify that the park brake shoes are not dragging on the brake drum. If park brake shoes are dragging, remove rotor and back off star wheel adjuster one notch and recheck for brake shoe drag against drum. Continue with the previous step until brake shoes are not dragging on brake drum. 13. Install disc brake caliper on caliper adapter (Fig. 150). 14. Install wheel and tire. 15. Tighten the wheel mounting nuts in the proper sequence until all nuts are torqued to half the specified torque. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 16. Lower vehicle. 17. Apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: Before moving vehicle, pump brake pedal several times to ensure the vehicle has a firm enough pedal to stop the vehicle. 18. Road test the vehicle to ensure proper function of the vehicle's brake system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 6168 Parking Brake Shoe: Service and Repair SHOES - PARKING BRAKE REMOVAL 1. AWD only - Set the parking brake. The parking brake is set to keep the hub/bearing and axle shaft from rotating when loosening the hub nut. 2. Raise vehicle. 3. Remove the wheel and tire assembly. 4. AWD only - Remove the cotter pin and nut retainer (Fig. 128) from the stub shaft of the outer C/V joint. 5. AWD only - Remove the spring washer (Fig. 129) from the stub shaft of the outer C/V joint. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 6169 6. AWD only - Remove the hub nut and washer (Fig. 130) from the stub shaft of the outer C/V joint. 7. Release the parking brake. 8. Create slack in the rear park brake cables by locking the out the automatic adjuster as described. Grasp the exposed section of front park brake cable and pull downward on it. Then install a pair of locking pliers on the front park brake cable just rearward of the second body outrigger bracket (Fig. 131). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 6170 9. Remove the disc brake caliper to adapter guide pin bolts (Fig. 132). 10. Remove rear caliper from adapter using the following procedure. First rotate front of caliper up from the adapter. Then pull the rear of the caliper and the outboard brake shoe anti-rattle clip out from under the rear abutment on the adapter (Fig. 133). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 6171 11. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose (Fig. 134). 12. Remove the rotor from the hub/bearing. 13. Remove the park brake cable mounting bolt to adapter. 14. Remove the end of the park brake cable from the actuator lever on the adapter (Fig. 135). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 6172 15. Remove the end of the park brake cable from the adapter. Park brake cable is removed from adapter using a 1/2" wrench slipped over the park brake cable retainer as show in (Fig. 136) to compress the locking tabs on the park brake cable retainer. 16. AWD only - Remove ABS wheel speed sensor head from hub/bearing (Fig. 137). 17. FWD only - Remove the ABS wheel speed sensor from the hub/bearing in the following fashion: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 6173 a. Remove secondary (yellow) retaining clip at rear of wheel speed sensor head (Fig. 138). b. Push up on metal retaining clip (Fig. 138) until it bottoms. This will release wheel speed sensor head from hub and bearing. While holding metal clip up, pull back on wheel speed sensor head removing it from hub and bearing. c. Remove wheel speed sensor from hub/bearing. 18. Remove the hub/bearing-to-axle mounting bolts (Fig. 139). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 6174 19. Remove the hub/bearing (Fig. 140). CAUTION: Corrosion may occur between the hub/bearing and the axle flange. If this occurs, the hub/bearing will be difficult to remove from the axle and disc brake caliper adapter. If the hub/bearing will not come out by pulling on it by hand, don't not pound on it with a hammer. Pounding on the hub/bearing will damage it. To remove a hub/bearing that is corroded in place, lightly tap the disc brake caliper adapter using a soft-face hammer. This will remove both the caliper adapter and hub/bearing together from the axle. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1, on the cast housing of hub/bearing (Fig. 141). Do not position the special tool on the inner race of hub/bearing. Lightly strike the Remover with a hammer to remove the hub/bearing from the caliper adapter. 20. Remove the adapter from the rear axle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 6175 21. Mount the adapter in a vise using the anchor boss for the park brake cable (Fig. 142). 22. Remove the lower return spring (Fig. 143) from the leading and trailing park brake shoes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 6176 23. Remove the hold down spring and pin (Fig. 144) from the leading park brake shoe. 24. Remove the adjuster (Fig. 145) from the leading and trailing park brake shoe. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 6177 25. Remove the leading park brake shoe (Fig. 146) from the adapter. Leading brake shoe is removed by rotating the bottom of the brake shoe inward (Fig. 146) until the top of the brake shoe can be removed from the brake shoe anchor. Then remove the upper return springs (Fig. 146) from the leading brake shoe. 26. Remove the upper return springs (Fig. 147) from the trailing park brake shoe. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 6178 27. Remove the hold down spring and pin (Fig. 148) from the trailing park brake shoe. 28. Remove the trailing park brake shoe from the adapter. 29. Remove the park brake shoe actuator from the adapter and inspect for signs of abnormal wear and binding at the pivot point. INSTALLATION 1. Install park brake shoe actuator into adapter. 2. Install the trailing brake shoe on the adapter. NOTE: When the hold down pin is installed, the long part of the hold down pin is to be positioned strait up and down. This will ensure that the hold down pin is correctly engaged with the adapter. 3. Install the hold down spring and pin (Fig. 148) on the trailing park brake shoe. 4. Install the upper return springs (Fig. 147) on the trailing park brake shoe. 5. Install the upper return springs on the leading park brake shoe (Fig. 146). Then position the top of the leading park brake shoe at the upper anchor and rotate the bottom of the shoe outward until correctly installed on the adapter. 6. Install the adjuster (Fig. 145) between the leading and trailing park brake shoe. NOTE: When the hold down pin is installed, the long part of the hold down pin is to be positioned strait up and down. This will ensure that the hold down pin is correctly engaged with the adapter. 7. Install the hold down spring and pin (Fig. 144) on the leading park brake shoe. 8. Install the lower return spring (Fig. 143) on the leading and trailing park brake shoes. When installing the return spring, it is to be installed behind the park brake shoes (Fig. 143). 9. Install the 4 mounting bolts for the adapter and hub/bearing into the bolt holes in the axle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Page 6179 10. Position the adapter on the 4 mounting bolts installed in the rear axle (Fig. 149). 11. Install the hub/bearing on the stub shaft of outer C/V joint (AWD only) and into the end of the axle. (Fig. 140). 12. In a progressive crisscross pattern, tighten the 4 hub/bearing mounting bolts until the hub/bearing is squarely seated against the axle. Then tighten the hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). 13. AWD only - Install the wheel speed sensor on the hub/bearing and adapter. Install the wheel speed sensor attaching bolt (Fig. 137). Tighten the wheel speed sensor attaching bolt to a torque of 12 Nm (105 inch lbs.). 14. FWD only - Install the wheel speed sensor in the following fashion: a. If metal wheel speed sensor retaining clip is not in the neutral installed position on hub and bearing cap, install from the bottom, if necessary, and push clip upward until it snaps into position. b. Install wheel speed sensor head into rear of hub and bearing aligning index tab with the notch in the top of the mounting hole. Push the sensor in until it snaps into place on the metal retaining clip. c. Install secondary (yellow) retaining clip over wheel speed sensor head and engage the tabs on each side. 15. Install the park brake cable into its mounting hole in the adapter. Be sure all the locking tabs on the park brake cable retainer are expanded out to ensure the cable will not pull out of the adapter. 16. Install the end of the park brake cable on the park brake actuator lever (Fig. 135). 17. Attach park brake cable to adapter using mounting bolt. 18. Remove the locking pliers (Fig. 131) from the front park brake cable. 19. Adjust the park brake drum-in-hat brake shoes. 20. Install the rotor on the hub/bearing. 21. Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse procedure for removal (Fig. 133). CAUTION: When installing guide pin bolts extreme caution should be taken not to crossthread the caliper guide pin bolts. 22. Install the caliper guide pin bolts (Fig. 132). Tighten the guide pin bolts to a torque of 35 Nm (26 ft. lbs.). 23. AWD only - Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and hub nut (Fig. 130) on the stub shaft of the outer C/V joint. 24. AWD only - Set the parking brake. 25. AWD only - Tighten the hub nut to a torque of 244 Nm (180 ft. lbs.). 26. AWD only - Install the spring washer (Fig. 129) on the stub shaft of the outer C/V joint. 27. AWD only - Install the nut retainer and cotter pin (Fig. 128) on the stub shaft of the outer C/V joint. 28. Install the wheel and tire assembly. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 29. Lower vehicle. 30. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a firm brake pedal to adequately stop vehicle. 31. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake shoe linings. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Locations Parking Brake Warning Lamp: Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Locations > Page 6183 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation Vacuum Brake Booster: Description and Operation POWER BRAKE BOOSTER DESCRIPTION The power brake booster mounts on the engine compartment side of the dash panel. It is connected to the brake pedal by the input (push) rod (Fig. 64). The master cylinder is bolted to the front of the booster. A vacuum line connects the power brake booster to the intake manifold. All Left-Hand-Drive (LHD) vehicles use a 270 mm single diaphragm vacuum power brake booster. All Right-Hand-Drive (RHD) vehicles use a 225/200 mm tandem diaphragm vacuum power brake booster. Vehicles equipped with Disc/Disc brakes use a different power brake booster than vehicles equipped with Disc/Drum brakes. Differences between the two are internal. Service is the same for all boosters. The power brake booster can be identified by the tag attached to the body of the booster (Fig. 65). This tag contains the production part number, the date it was built, and who the manufacturer of the power brake booster is. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 6188 NOTE: The power brake booster assembly is not a repairable component and must be replaced as a complete assembly if found to be faulty in any way. The check valve located on the power brake booster face is not repairable, but it can be replaced separately from the power brake booster. The different engine combinations used in this vehicle require different vacuum hose routings to the power brake booster. All vacuum hoses must be routed from the engine to the power brake booster without kinks or excessively tight bends. OPERATION The power brake booster reduces the amount of force required by the driver to obtain the necessary hydraulic pressure to stop a vehicle. The power brake booster is vacuum operated. The vacuum is supplied from the intake manifold on the engine through a vacuum hose and the power brake booster check valve (Fig. 64). As the brake pedal is depressed, the power brake booster's input rod moves forward (Fig. 64). This opens and closes valves in the power booster allowing atmospheric pressure to enter on one side of a diaphragm. Engine vacuum is always present on the other side. This difference in pressure forces the output rod of the power brake booster out against the primary piston of the master cylinder. As the pistons in the master cylinder move forward this creates the hydraulic pressure in the brake system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 6189 Vacuum Brake Booster: Testing and Inspection DIAGNOSIS AND TESTING - POWER BRAKE BOOSTER BASIC TEST 1. With engine off, depress and release the brake pedal several times to purge all vacuum from the power brake booster. 2. Depress and hold the pedal with light effort (15 to 25 lbs. pressure), then start the engine. The pedal should fall slightly, then hold. Less effort should be needed to apply the pedal at this time. If the pedal fell as indicated, perform the VACUUM LEAK TEST listed after the BASIC TEST. If the pedal did not fall, continue on with this BASIC TEST. 3. Disconnect the vacuum hose on the vacuum check valve, then place a vacuum gauge in line between the vacuum hose and the valve. 4. Start the engine. 5. When the engine is at warm operating temperature, allow it to idle and check the vacuum at the gauge. If the vacuum supply is 12 inches Hg (40.5 kPa) or more, the power brake booster is defective and must be replaced. If the vacuum supply is below 12 inches Hg, continue on with this BASIC TEST. 6. Shut off the engine. 7. Connect the vacuum gauge to the vacuum reference port on the engine intake manifold. 8. Start the engine and observe the vacuum gauge. If the vacuum is still low, check the engine tune and repair as necessary. If the vacuum is above 12 inches Hg, the hose or check valve to the booster has a restriction or leak. Once an adequate vacuum supply is obtained, repeat the BASIC TEST. VACUUM LEAK TEST 1. Disconnect the vacuum hose on the vacuum check valve, then place a vacuum gauge in line between the vacuum hose and the valve. 2. Start the engine. 3. Allow the engine to warm up to normal operating temperature and engine idle. 4. Using vacuum line pliers, close off the vacuum supply hose near the booster, but before the vacuum gauge, then observe the vacuum gauge. If the vacuum drop exceeds 1.0 inch Hg (3.3 kPa) in one minute, repeat the above steps to confirm the reading. The vacuum loss should be less than 1.0 inch Hg in one minute time span. If the loss is more than 1.0 inch Hg, replace the power brake booster. If it is not, continue on with this test. 5. Remove the pliers from the hose temporarily. 6. Apply light effort (approximately 15 lbs. of force) to the brake pedal and hold the pedal steady. Do not move the pedal once the pressure is applied or the test results may vary. 7. Have an assistant reattach the vacuum line pliers to the vacuum supply hose. 8. Allow 5 seconds for stabilization, then observe the vacuum gauge. If the vacuum drop exceeds 3.0 inches Hg (10 kPa) in 15 seconds, repeat the above steps to confirm the reading. The vacuum loss should be less than 3.0 inches Hg in 15 seconds time span. If the loss is more than 3.0 inches Hg, replace the power brake booster. If it is not, the booster is not defective. 9. Remove the pliers and vacuum gauge. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > LHD Vacuum Brake Booster: Service and Repair LHD POWER BRAKE BOOSTER REMOVAL - LHD CAUTION: Reserve vacuum in power brake booster must be pumped down (removed) before removing master cylinder from booster. This is necessary to prevent booster from sucking in any contamination as master cylinder is removed. This can be done simply by pumping the brake pedal, with the vehicle's engine not running, until a firm feeling brake pedal is achieved. 1. With engine not running, pump the brake pedal until a firm pedal is achieved (4-5 strokes). 2. Remove negative battery cable terminal from battery. 3. Remove positive battery cable terminal from battery. 4. Remove battery thermal guard shield. 5. Remove battery clamp, nut and battery from the battery tray. 6. Remove screw securing engine coolant filler tube to battery tray. 7. If the vehicle is equipped with speed control, disconnect the vacuum hose at the vacuum tank built into the battery tray. 8. Remove the two nuts and one bolt securing battery tray in place. Remove battery tray. 9. If vehicle is equipped with speed control: a. Disconnect wiring harness connector from the speed control servo. b. Remove the two servo mounting nuts. c. Lay speed control servo off to the side, out of the way. 10. Remove the wiper module (unit). 11. Disconnect wiring harness connector from brake fluid level switch in master cylinder fluid reservoir (Fig. 66). CAUTION: Before removing the master cylinder from the power brake vacuum booster, the master cylinder and vacuum booster must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the power brake vacuum booster. 12. Clean area where master cylinder assembly attaches to power brake booster. Use only a solvent such as Mopar Brake Parts Cleaner or equivalent. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > LHD > Page 6192 13. Disconnect primary and secondary brake tubes from ABS integrated control unit or non-ABS junction block (Fig. 67). Install sealing plugs in the now open brake tube ports and install caps on ends of tubes. NOTE: It is not necessary to remove the brake tubes from the master cylinder when removing the master cylinder from the vacuum booster. 14. Remove two nuts attaching master cylinder to power brake booster (Fig. 67). 15. Slide master cylinder straight out of power brake booster. Remove master cylinder with primary and secondary tubes from vehicle. CAUTION: A seal on the rear of the master cylinder is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal on the master cylinder MUST be replaced whenever the master cylinder is removed from the power brake vacuum booster. 16. Disconnect vacuum hose from check valve located on vacuum booster. DO NOT REMOVE CHECK VALVE FROM POWER BRAKE BOOSTER. 17. Inside vehicle, remove silencer panel under instrument panel below steering column. 18. Locate the booster input rod to brake pedal connection under the instrument panel. Position a small screwdriver between the center tang on the power brake booster input rod to brake pedal pin retaining clip (Fig. 68). 19. Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin. Then pull retaining clip off brake pedal pin. Discard retaining clip. It is not to be reused. Replace only with a new retaining clip when assembling. 20. Slide booster input rod off pedal pin. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > LHD > Page 6193 21. Remove the four nuts attaching power brake booster to dash panel (Fig. 69). 22. Slide power brake booster forward and remove through engine compartment (Fig. 70). CAUTION: Do not attempt to disassemble the power brake vacuum booster. It is serviced ONLY as a complete assembly. INSTALLATION - LHD 1. Position power brake booster on dash panel using the reverse procedure of its removal (Fig. 70). It may be necessary to push in on booster input rod as it is guided through the dash panel. 2. Install the four nuts mounting the booster to the dash panel (Fig. 69). Tighten the mounting nuts to a torque of 29 Nm (250 inch lbs.). 3. Using lubriplate, or equivalent, coat the surface of the brake pedal pin where it contacts the booster input rod. CAUTION: When installing the brake pedal pin on the power brake booster input rod, do not re-use the old retaining clip. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > LHD > Page 6194 4. Install booster input rod on brake pedal pin and install a NEW retaining clip (Fig. 76). CAUTION: Do not reuse the original brake lamp switch. The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. 5. Remove and replace the brake lamp switch with a NEW switch. 6. Install the silencer panel below the steering column. 7. Connect vacuum hose to check valve on power brake booster. CAUTION: The master cylinder (and its rear seal) is used to create the seal for holding vacuum in the vacuum booster. The vacuum seal on the master cylinder MUST be replaced with a NEW seal whenever the master cylinder is removed from the vacuum booster. CAUTION: When removing the vacuum seal from the master cylinder do not use a sharp tool. 8. Using a soft tool such as a trim stick, remove the vacuum seal from the master cylinder mounting flange. 9. Install a NEW vacuum seal on rear mounting flange of the master cylinder (Fig. 77). 10. Position master cylinder on studs of booster, aligning push rod on booster with master cylinder piston. 11. Install the two nuts mounting the master cylinder to the booster (Fig. 67). Tighten both mounting nuts to a torque of 25 Nm (225 inch lbs.). 12. Connect wiring harness connector to brake fluid level switch in the master cylinder fluid reservoir (Fig. 66). 13. Connect primary and secondary brake tubes to ABS ICU or non-ABS junction block (Fig. 67). Tighten the tube nuts to 17 Nm (145 in lbs.). 14. Install wiper module (unit). 15. If equipped with speed control, install speed control servo and connect wiring connector. Tighten the mounting nuts to a torque of 14 Nm (124 inch lbs.). 16. Install the battery tray. Install the two nuts and one bolt attaching the battery tray to the vehicle. Tighten the bolt and nuts to a torque of 14 Nm (124 inch lbs.). 17. If vehicle is equipped with speed control, connect the servo vacuum hose to the vacuum tank on the battery tray. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > LHD > Page 6195 18. Install the air inlet resonator and hoses as an assembly on the throttle body and air cleaner housing. Securely tighten hose clamp at air cleaner housing and throttle body. 19. Secure the engine coolant filler neck to the battery tray with its mounting screw. 20. Install the battery, clamp and mounting nut. 21. Install the positive battery cable on the battery. 22. Install the negative battery cable on the battery. 23. Install the battery thermal guard shield. 24. Bleed the base brakes as necessary. 25. Road test vehicle to ensure operation of the brakes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > LHD > Page 6196 Vacuum Brake Booster: Service and Repair RHD POWER BRAKE BOOSTER REMOVAL - RHD CAUTION: Reserve vacuum in power brake booster must be pumped down (removed) before removing master cylinder from booster. This is necessary to prevent booster from sucking in any contamination as master cylinder is removed. This can be done simply by pumping the brake pedal, with the vehicle's engine not running, until a firm feeling brake pedal is achieved. 1. With engine not running, pump the brake pedal until a firm pedal is achieved (4 or 5 strokes). 2. Remove negative battery cable terminal from battery. 3. Remove positive battery cable terminal from battery. 4. Remove battery thermal guard shield. 5. Remove battery clamp, nut and battery from the battery tray. 6. If the vehicle is equipped with speed control, disconnect the vacuum hose at the vacuum tank built into the battery tray. 7. Remove the two nuts and one bolt securing battery tray in place. Remove battery tray. 8. If vehicle is equipped with speed control: a. Disconnect wiring harness connector from the speed control servo. b. Remove the two servo mounting nuts. c. Lay speed control servo off to the side, out of the way. 9. If the vehicle is equipped with the 2.5L diesel engine, remove the coolant recovery pressure container and bracket. 10. Disconnect wiring harness connector from brake fluid level switch in master cylinder fluid reservoir (Fig. 71). CAUTION: Before removing the master cylinder from the power brake vacuum booster, the master cylinder and vacuum booster must be thoroughly cleaned. This must be done to prevent dirt particles from falling into the power brake vacuum booster. 11. Clean area where master cylinder assembly attaches to power brake booster. Use only a solvent such as Mopar Brake Parts Cleaner or equivalent. NOTE: It is not necessary to remove the brake tubes from the master cylinder when removing the master cylinder from the booster. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > LHD > Page 6197 12. Remove two nuts attaching master cylinder to power brake booster (Fig. 72). 13. Slide master cylinder straight out of power brake booster. Lay master cylinder with primary and secondary tubes to the side, out of the way. CAUTION: A seal on the rear of the master cylinder is used to create the seal for holding vacuum in the power brake vacuum booster. The vacuum seal on the master cylinder MUST be replaced whenever the master cylinder is removed from the power brake vacuum booster. 14. Disconnect vacuum hose from check valve located on booster. DO NOT REMOVE CHECK VALVE FROM POWER BRAKE BOOSTER. 15. Under the instrument panel, remove booster input rod trim cover. 16. Locate the booster input rod to brake pedal torque shaft connection under the instrument panel. Position a small screwdriver between the center tang on the retaining clip (Fig. 73). 17. Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal pin. Then pull retaining clip off brake pedal torque shaft pin. Discard retaining clip. It is not to be reused. Replace only with a new retaining clip when assembling. 18. Remove booster input rod from pedal torque shaft pin. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > LHD > Page 6198 19. Remove the three easily accessed mounting nuts attaching power brake booster to dash panel and loosen fourth (Fig. 74). As fourth nut is loosened, push the booster forward periodically until the nut can be completely removed. 20. Slide power brake booster forward and remove through engine compartment (Fig. 75). CAUTION: Do not attempt to disassemble the power brake vacuum booster. It is serviced ONLY as a complete assembly. INSTALLATION - RHD 1. Position power brake booster on dash panel using the reverse procedure of its removal (Fig. 75). 2. Below instrument panel, first install the two upper nuts mounting the booster to the dash panel, drawing it into place, then install the two lower mounting nuts. Tighten the mounting nuts to a torque of 29 Nm (250 inch lbs.). 3. Using lubriplate, or equivalent, coat the surface of the brake pedal torque shaft pin where it contacts the booster input rod. CAUTION: When installing the brake pedal torque shaft pin on the power brake booster input rod, do not re-use the old retaining clip. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > LHD > Page 6199 4. Install booster input rod on brake pedal torque shaft pin and install a NEW retaining clip (Fig. 78). 5. Install booster input rod trim cover. 6. Connect vacuum hose to check valve on power brake booster. CAUTION: The master cylinder (and its rear seal) is used to create the seal for holding vacuum in the vacuum booster. The vacuum seal on the master cylinder MUST be replaced with a NEW seal whenever the master cylinder is removed from the vacuum booster. CAUTION: When removing the vacuum seal from the master cylinder, do not use a sharp tool. 7. Using a soft tool such as a trim stick, remove the vacuum seal from the master cylinder mounting flange. 8. Install a NEW vacuum seal on rear mounting flange of the master cylinder (Fig. 79). 9. Position master cylinder on studs of booster, aligning push rod on booster with master cylinder piston. 10. Install the two nuts mounting the master cylinder to the booster (Fig. 72). Tighten both mounting nuts to a torque of 25 Nm (225 inch lbs.). 11. Connect wiring harness connector to brake fluid level switch in the master cylinder fluid reservoir (Fig. 71). 12. If the vehicle is equipped with the 2.5L diesel engine, install the coolant recovery pressure container and bracket. 13. If equipped with speed control, install speed control servo and connect wiring connector. Tighten the mounting nuts to a torque of 14 Nm (124 inch lbs.). 14. Install the battery tray. Install the two nuts and one bolt attaching the battery tray to the vehicle. Tighten the bolt and nuts to a torque of 14 Nm (124 inch lbs.). 15. If vehicle is equipped with speed control, connect the servo vacuum hose to the vacuum tank on the battery tray. 16. Install the battery, clamp and mounting nut. 17. Install the positive battery cable on the battery. 18. Install the negative battery cable on the battery. 19. Install the battery thermal guard shield. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > LHD > Page 6200 CAUTION: Do not reuse the original brake lamp switch. The switch can only be adjusted once. That is during initial installation of the switch. If the switch is not adjusted properly or has been removed for some service, a new switch must be installed and adjusted. 20. Remove and replace the brake lamp switch with a NEW switch. 21. Bleed the base brakes as necessary. 22. Road test vehicle to ensure proper operation of the brakes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 6205 3.3-3.8 Liter Engine Front Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 6206 Electronic Brake Control Module: Diagrams Anti-Lock Brake Module(MK25e) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 6207 Controller ANTILOCK Brake (MK20E) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > System Overview Electronic Brake Control Module: Description and Operation System Overview CONTROLLER ANTILOCK BRAKE/ANTI-LOCK BRAKE MODULE The CAB/ABM is a microprocessor-based device that monitors wheel speeds and controls the antilock functions. The CAB/ABM contains two microprocessors that receive identical sensor signals and then independently process the information. The results are then compared to make sure that they agree. Otherwise, the CAB/ABM will turn off the antilock and turn on the ABS amber warning indicator. The primary functions of the CAB/ABM are to: ^ detect wheel locking tendencies ^ control fluid pressure modulation to the brakes during antilock stop ^ monitor the system for proper operation ^ manage traction control functions ^ provide communication to the DRBIII(R) while in diagnostic mode ^ store diagnostic information in non-volatile memory The CAB/ABM continuously monitors the speed of each wheel. When a wheel locking tendency is detected, the CAB/ABM will command the appropriate valve to modulate brake fluid pressure in its hydraulic unit. Brake pedal position is maintained during an antilock stop by being a closed system. The CAB/ABM continues to control pressure in individual hydraulic circuits until a wheel locking tendency is no longer present. The CAB/ABM turns on the pump motor during an antilock stop. The antilock brake system is constantly monitored by the CAB/ABM for proper operation. If the CAB/ABM detects a system malfunction, it can disable the antilock system and turn on the ABS warning indicator. If the antilock function is disabled, the system will revert to standard base brake system operation. The CAB/ABM inputs include the following: ^ diagnostic communication ^ four wheel speed sensors ^ three power feeds: valve, pump, and microprocessor ^ brake lamp switch ^ traction control switch The CAB/ABM outputs include the following: ^ ABS warning indicator actuation ^ 12 volts supply to wheel speed sensors ^ valve actuation ^ diagnostic communication ^ PCI bus communication ^ traction control lamp illumination Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > System Overview > Page 6210 Electronic Brake Control Module: Description and Operation Antilock Brake Module (MK25E) The Antilock Brake Module (ABM) is a microprocessor-based device which monitors the antilock brake system (ABS) during normal braking and controls it when the vehicle is in an ABS stop or when in a traction control situation. The ABM utilizes a 47-way electrical connector on the vehicle wiring harness. The power source for the ABM is through the ignition switch in the RUN or ON position. Mk25e ICU The ABM is mounted to the HCU as part of the Integrated Control Unit (ICU). The ICU is located in the engine compartment below the master cylinder on the front suspension cradle/crossmember. The primary functions of the Antilock Brake Module (ABM) are to: - Monitor the antilock brake system for proper operation. - Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - Control fluid modulation to the wheel brakes while the system is in an ABS mode. - Store diagnostic information. - Provide communication to the scan tool while in diagnostic mode. - Illuminate the amber ABS warning indicator lamp. - (With traction control only) Illuminate the TRAC ON lamp in the message center on the instrument panel when a traction control event occurs. - (with traction control only) Illuminate the TRAC OFF lamp when the amber ABS warning indicator lamp illuminates. The ABM constantly monitors the antilock brake system for proper operation. If the ABM detects a fault, it will turn on the amber ABS warning indicator lamp and disable the antilock braking system. The normal base braking system will remain operational. NOTE: If the vehicle is equipped with traction control, the TRAC OFF lamp will illuminate anytime the amber ABS warning indicator lamp illuminates. The ABM continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the ABM commands the ABM command coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The ABM continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The ABM contains a self-diagnostic program that monitors the antilock brake system for system faults. When a fault is detected, the amber ABS warning indicator lamp is turned on and the fault diagnostic trouble code (DTC) is then stored in a diagnostic program memory. A latched fault will disable certain system functionality for the current ignition cycle. An unlatched fault will disable certain system functionality until the fault condition disappears. These DTC's will remain in the ABM memory even after the ignition has been turned off. The DTC's can be read and cleared from the ABM memory by a technician using a scan tool. If not cleared with a scan tool, the fault occurrence and DTC will be automatically cleared from the ABM memory after the identical fault has not been seen during the next 3,500 miles. Drive-off may be required for the amber ABS warning indicator lamp to go out on the next ignition cycle. ABM INPUTS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > System Overview > Page 6211 - Wheel speed sensors (four) - Brake lamp switch - Ignition switch - System and pump voltage - Ground - Traction control switch (if equipped) - Diagnostic communication (PCI) ABM OUTPUTS - Amber ABS warning indicator lamp actuation (via BUS) - Red BRAKE warning indicator lamp actuation (via BUS) - Instrument cluster (MIC) communication (PCI) - Traction control lamps (if equipped) - Diagnostic communication (PCI, via BUS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > System Overview > Page 6212 Electronic Brake Control Module: Description and Operation Controller Antilock Brake (MK20E) Integrated Control Unit (ICU) The controller antilock brake (CAB) is a microprocessor-based device which monitors the antilock brake system (ABS) during normal braking and controls it when the vehicle is in an ABS stop. The CAB is mounted to the HCU as part of the integrated control unit (ICU). The CAB uses a 24-way electrical connector on the vehicle wiring harness. The power source for the CAB is through the ignition switch in the RUN or ON position. The CAB is on the PCI bus. The primary functions of the controller antilock brake (CAB) are to: - Monitor the antilock brake system for proper operation. - Detect wheel locking or wheel slipping tendencies by monitoring the speed of all four wheels of the vehicle. - Control fluid modulation to the wheel brakes while the system is in an ABS mode. - Store diagnostic information. - Provide communication to the DRBIII(R) scan tool while in diagnostic mode. - Illuminate the amber ABS warning indicator lamp. - (With traction control only) Illuminate the TRAC ON lamp in the message center on the instrument panel when a traction control event occurs. - (with traction control only) Illuminate the TRAC OFF lamp when the amber ABS warning indicator lamp illuminates. The CAB constantly monitors the antilock brake system for proper operation. If the CAB detects a fault, it will turn on the amber ABS warning indicator lamp and disable the antilock braking system. The normal base braking system will remain operational. NOTE: If the vehicle is equipped with traction control, the TRAC OFF lamp will illuminate anytime the amber ABS warning indicator lamp illuminates. The CAB continuously monitors the speed of each wheel through the signals generated by the wheel speed sensors to determine if any wheel is beginning to lock. When a wheel locking tendency is detected, the CAB commands the CAB command coils to actuate. The coils then open and close the valves in the HCU that modulate brake fluid pressure in some or all of the hydraulic circuits. The CAB continues to control pressure in individual hydraulic circuits until a locking tendency is no longer present. The CAB contains a self-diagnostic program that monitors the antilock brake system for system faults. When a fault is detected, the amber ABS warning indicator lamp is turned on and the fault diagnostic trouble code (DTC) is then stored in a diagnostic program memory. A latched fault will disable certain system functionality for the current ignition cycle. An unlatched fault will disable certain system functionality until the fault condition disappears. These DTC's will remain in the CAB memory even after the ignition has been turned off. The DTC's can be read and cleared from the CAB memory by a technician using the DRBIII(R) scan tool. If not cleared with a DRBIII(R) scan tool, the fault occurrence and DTC will be automatically cleared from the CAB memory after the identical fault has not been seen during the next 3,500 miles. Drive-off may be required for the amber ABS warning indicator lamp to go out on the next ignition cycle. CAB INPUTS - Wheel speed sensors (four) - Brake lamp switch - Ignition switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > System Overview > Page 6213 - System and pump voltage - Ground - Traction control switch (if equipped) - Diagnostic communication (PCI) CAB OUTPUTS - Amber ABS warning indicator lamp actuation (via BUS) - Red BRAKE warning indicator lamp actuation (via BUS) - Instrument cluster (MIC) communication (PCI) - Traction control lamps (if equipped) - Diagnostic communication (PCI, via BUS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Brake Module (MK25E) Electronic Brake Control Module: Service and Repair Antilock Brake Module (MK25E) REMOVAL 1. Disconnect the negative (ground) cable from the battery and isolate it. 2. Remove the battery shield and battery. 3. Disconnect the vacuum hose connector at the tank built into the battery tray. 4. Remove the screw securing the engine coolant filler neck to the battery tray. 5. Remove the battery tray. CAUTION: Before disassembling the ICU, the ICU must be thoroughly cleaned. This must be done to prevent dirt particles and debris from entering into vital areas of the ICU. 6. Thoroughly clean all surfaces of the ICU and brake tubes. Use only a solvent such as Mopar Brake Parts Cleaner or equivalent. ABM Connector Release Tabs Wiring Harness Connector At ABM 7. Disconnect the 47-way connector from the antilock brake module (ABM) by depressing the tabs on each side of the connector cover (Fig. 2), then pulling outward and upward on the lower half of the cover until it locks into position pointing straight outward. The connector can then be pulled straight outward off the ABM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Brake Module (MK25E) > Page 6216 ABM Mounting Screws - Without Traction Control 8. If not equipped with traction control, remove the three screws attaching the ABM to the HCU. ABM Mounting Screws - With Traction Control 9. If equipped with traction control, remove the four screws attaching the ABM to the HCU. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Brake Module (MK25E) > Page 6217 ABM Assembly To HCU 10. Separate the ABM from the HCU. INSTALLATION 1. Clean any debris off the mating surfaces of the HCU and ABM. CAUTION: - Do not reuse internal pump connector O-ring or solenoid valve stem seals. They must be replaced to ensure proper sealing. - When installing new O-rings or solenoid valve stem seals, do not use any type of lubricant. Solenoid Valve Seal 2. Replace solenoid valve stem seals. These seals can be easily removed and installed by hand. Do not use any type of sharp instrument or damage to the components may occur. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Brake Module (MK25E) > Page 6218 Internal Pump Connector O-Ring 3. Replace pump/motor connector O-ring if not new. 4. Align components and install the ABM on the HCU. 5. If not equipped with traction control, install the three screws attaching the ABM to the HCU. Tighten the mounting screws to 2 N.m (17 in. lbs.) torque. 6. If equipped with traction control, install the four screws attaching the ABM to the HCU. Tighten the mounting screws to 2 N.m (17 in. lbs.) torque. 7. With connector cover completely open, install 47-way wiring connector into socket of the ABM and close cover, locking connector in place. 8. Install the battery tray. 9. Install the screw securing the coolant filler neck to the battery tray. 10. Reconnect the vacuum hose connector at the tank built into the battery tray. 11. Install the battery and battery shield. 12. Connect the negative cable on the battery negative post. 13. Hook up a scan tool to initialize ABM and check for any faults. 14. Road test vehicle to ensure proper operation of brakes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Brake Module (MK25E) > Page 6219 Electronic Brake Control Module: Service and Repair Controller Antilock Brake (MK20E) REMOVAL 1. Disconnect the battery cables. 2. Remove the battery. 3. Disconnect the vacuum hose connector at the tank built into the battery tray. 4. Remove the screw securing the coolant filler neck to the battery tray. 5. Remove the battery tray. CAB Connector Lock 6. Pull up on the CAB connector lock and disconnect the 24-way electrical connector. 7. Disconnect the pump/motor connector from the CAB. CAB Mounting Screws 8. Remove the screws securing the CAB to the HCU. 9. Pull CAB straight forward off HCU. INSTALLATION 1. Slide the CAB onto the HCU. 2. Install screws securing the CAB to the HCU. Tighten the mounting screws to 2 N.m (17 in lbs). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Antilock Brake Module (MK25E) > Page 6220 3. Reconnect the 24-way wiring connector and the pump/motor wiring connector. 4. Install the battery tray. 5. Install the screw securing the coolant filler neck to the battery tray. 6. Reconnect the vacuum hose to the coolant tank built into the battery tray. 7. Install the battery. 8. Reconnect the battery cables. 9. Connect a DRBIII(R) to the vehicle. Check and clear any faults, and initialize the system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Left Side Engine Compartment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6225 Brake Fluid Level Sensor/Switch: Description and Operation BRAKE FLUID LEVEL SWITCH DESCRIPTION The brake fluid level switch is located in the brake fluid reservoir of the master cylinder (Fig. 3). OPERATION The purpose of the brake fluid level switch is to provide the driver with an early warning that the brake fluid level in the master cylinder fluid reservoir has dropped below a normal level. This may indicate: ^ Abnormal loss of brake fluid in the master cylinder fluid reservoir resulting from a leak in the hydraulic system. ^ Brake shoe linings which have worn to a point requiring replacement. As the brake fluid drops below the minimum level, the brake fluid level switch closes to complete the red BRAKE warning indicator (lamp) circuit. This will turn on the red BRAKE warning indicator. The master cylinder fluid reservoir should be checked and refilled to the Full mark with DOT 3 brake fluid. If the brake fluid level has dropped below the add line in the master cylinder fluid reservoir, the entire brake hydraulic system should be checked for evidence of a leak. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 6226 Brake Fluid Level Sensor/Switch: Service and Repair BRAKE FLUID LEVEL SWITCH REMOVAL 1. Remove wiring harness connector from brake fluid reservoir level switch (Fig. 3). 2. Using fingers, compress the retaining tabs on the opposite end of brake fluid level switch. 3. With retaining tabs compressed, grasp the connector end of brake fluid level switch and pull it out of master cylinder brake fluid reservoir. INSTALLATION 1. Insert brake fluid level switch into left side of brake fluid reservoir. Be sure switch is pushed in until retaining tabs lock it to brake fluid reservoir. 2. Connect vehicle wiring harness connector to brake fluid level switch (Fig. 3). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Diagrams Brake Fluid Level Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations > Page 6234 Traction Control Switch: Connector Locations Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Component Locations > Page 6235 Steering Column Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 6236 Traction Control Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 6237 Traction Control Switch: Testing and Inspection TRACTION CONTROL SWITCH DIAGNOSIS AND TESTING - TRACTION CONTROL SWITCH 1. Remove lower steering column shroud. 2. Disconnect traction control switch harness from column harness (Fig. 5). 3. Using an ohmmeter, check for continuity between pins 1 and 2. With the switch actuated, there should be continuity between the two pins. With the switch off, there should be no continuity. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 6238 Traction Control Switch: Service and Repair TRACTION CONTROL SWITCH REMOVAL The traction control switch is located in the upper shroud. Refer to Steering. INSTALLATION The traction control switch is located in the upper shroud. Refer to Steering. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Brakes - Rear Wheel Speed Sensor Replacement Guidelines Wheel Speed Sensor: Technical Service Bulletins Brakes - Rear Wheel Speed Sensor Replacement Guidelines NUMBER: 05-004-04 REV. A GROUP: Brakes DATE: December 3, 2004 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-004-04, DATED SEPTEMBER 2, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS. SUBJECT: Anti-lock Brake Rear Wheel Speed Sensor Replacement MODELS: **2001 - 2005 (RG) Chrysler Voyager** 2001 - 2005 (RS) Town & Country/Caravan/Voyager NOTE: This bulletin applies to non-all wheel drive vehicles equipped with anti-lock brakes (sales code BGF). PARTS REQUIRED: DISCUSSION: When replacing a rear wheel speed sensor, upon disassembly, inspect for moisture on the sensor and inside the bearing cap. If moisture is present, the moisture must be dried out prior to reassembly, or the new sensor may be damaged. When installing a replacement wheel speed sensor, be sure to lubricate the sensor 0-ring and the sensor head completely, with Mopar wheel bearing grease, p/n 05083149AA, before installation. NOTE: It is important that only Mopar, p/n 05083149AA, Wheel Bearing Grease, or M56560 equivalent, be used for this application. No other lubricant may be substituted. Other lubricants may cause sensor damage. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Technical Service Bulletins > Page 6243 Wheel Speed Sensor: Specifications TONE WHEEL RUNOUT WHEEL SPEED SENSOR AIR GAP Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations Wheel Speed Sensor: Component Locations WHEEL SPEED SENSORS FRONT REAR WHEEL SPEED SENSOR CONNECTORS FRONT Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 6246 REAR Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 6247 Wheel Speed Sensor: Connector Locations Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 6248 Left Fender Shield Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 6249 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 6250 Left Rear Body Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Component Locations > Page 6251 Right Quarter Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 6252 Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor Left Rear Wheel Speed Sensor Right Front Wheel Speed Sensor Right Rear Wheel Speed Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 6253 Wheel Speed Sensor: Description and Operation ABS SWITCHES/SENSORS Wheel Speed Sensors and Tone Wheels: One active wheel speed sensor (WSS) is located at each wheel. The sensors use an electronic principle known as magneto-resistive to help increase performance, durability and low speed accuracy. The sensors convert wheel speed into a small digital signal. A toothed gear tone wheel serves as the trigger mechanism for each sensor. The CAB/ABM sends 12 volts to power an Integrated Circuit 01C) in the sensor. The IC supplies a constant 7 mA signal to the CAB/ABM. The relationship of the tooth on the tone wheel to the permanent magnet in the sensor, signals the IC of the sensor to toggle a second 7 mA power supply on or off. The output of the sensor, sent to the CAB/ ABM, is a DC voltage signal with changing voltage and current levels. The CAB/ABM monitors the changing amperage (digital signal) from each wheel speed sensor. The resulting signal is interpreted by the CAB/ABM as the wheel speed. Because of internal circuitry, correct wheel speed sensor function cannot be determined by a continuity or resistance check through the sensor. Correct antilock system operation is dependent on tone wheel speed signals from the wheel speed sensors. The vehicle's wheels and tires should all be the same size and type to generate accurate signals. In addition, the tires should be inflated to the recommended pressure for optimum system operation. Variation in wheel and tire size or significant variations in inflation pressure can produce inaccurate wheel speed signals; however, the system will continue to function when using the correct factory mini-spare. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Page 6254 Wheel Speed Sensor: Testing and Inspection TONE WHEEL INSPECTION - TONE WHEEL NOTE: Rear tone wheels for front-wheel-drive vehicles are sealed within the hub and bearing assembly and cannot be inspected or replaced. Replacement of the hub and bearing is necessary. Tone wheels can cause erratic wheel speed sensor signals. Inspect tone wheels for the following possible causes. ^ missing, chipped, or broken teeth ^ contact with the wheel speed sensor ^ wheel speed sensor to tone wheel alignment ^ wheel speed sensor to tone wheel clearance ^ excessive tone wheel runout ^ tone wheel loose on its mounting surface If a front tone wheel is found to need replacement, the drive shaft must be replaced. No attempt should be made to replace just the tone wheel. If wheel speed sensor to tone wheel contact is evident, determine the cause and correct it before replacing the wheel speed sensor or tone wheel. Check the gap between the speed sensor head and the tone wheel to ensure it is within specifications. Excessive wheel speed sensor runout can cause erratic wheel speed sensor signals. Refer to SPECIFICATIONS for the maximum allowed tone wheel runout. If tone wheel runout is excessive, determine if it is caused by a defect in the driveshaft assembly or hub and bearing. Replace as necessary. Tone wheels are pressed onto their mounting surfaces and should not rotate independently from the mounting surface. Replacement of entire component is necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front Wheel Speed Sensor: Service and Repair Front FRONT WHEEL SPEED SENSOR REMOVAL 1. Raise vehicle. 2. Remove the tire and wheel assembly. 3. Remove the sensor cable routing clamp screws. CAUTION: When disconnecting the wheel speed sensor from vehicle wiring harness, be careful not to damage pins on connector 4. Remove speed sensor cable grommets from intermediate bracket on strut. 5. Disconnect speed sensor cable from vehicle wiring harness behind fender well shield. 6. Remove the wheel speed sensor head mounting bolt (Fig. 1). 7. Remove sensor head from steering knuckle. If sensor has seized due to corrosion, DO NOT USE PLIERS ON SENSOR HEAD. Use a hammer and a punch and tap edge of sensor ear, rocking the sensor side-to-side until free. 8. Remove front wheel speed sensor from vehicle. INSTALLATION CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as shown may result in contact with moving parts and over extension of cables, resulting in an open circuit. 1. Connect the front wheel speed sensor cable to the vehicle wiring harness connector. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector. 2. Install the bolts attaching the routing clamps to the body of the vehicle. Tighten the bolts to a torque of 14 Nm (125 inch lbs.). 3. Insert speed sensor cable grommets into intermediate bracket on strut. 4. Install the wheel speed sensor head mounting bolt (Fig. 1). Tighten the bolt to a torque of 13 Nm (115 inch lbs.) 5. Install the wheel and tire assembly on vehicle. 6. Lower vehicle. 7. Road test vehicle to ensure proper operation of the base and ABS brake systems. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 6257 Wheel Speed Sensor: Service and Repair Rear Rear Wheel Speed Sensor - FWD REAR WHEEL SPEED SENSOR - FWD REMOVAL 1. Raise vehicle. CAUTION: When disconnecting speed sensor cable from vehicle wiring harness be careful not to damage pins on the electrical connectors. Also, inspect connectors for any signs of previous damage. 2. Remove grommet from floor pan of vehicle and disconnect speed sensor cable connector from vehicle wiring harness (Fig. 2). CAUTION: When removing rear wheel speed sensor cable from routing clips, be sure not to damage the routing clips. Routing clips that are molded onto the brake hose will require replacement of the brake hose if damaged during removal or installation of the speed sensor cable. 3. Carefully remove speed sensor cable from press-in routing clips (Fig. 3). 4. Remove bolt securing metal routing clip to rear of axle and remove sensor cable from metal clip (Fig. 3). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 6258 5. Remove secondary (yellow) retaining clip at rear of wheel speed sensor head (Fig. 4). 6. Push up on metal retaining clip (Fig. 4) until it bottoms. This will release wheel speed sensor head from hub and bearing. While holding metal clip up, pull back on wheel speed sensor head removing it from hub and bearing. 7. Remove wheel speed sensor assembly from vehicle. INSTALLATION CAUTION: Proper installation of wheel speed sensor cable is critical to continued system operation. Be sure that cable is installed in routing retainers/clips. Failure to install cable in retainers may result in contact with moving parts or over extension of cable, resulting in an open circuit. CAUTION: It is important that only Mopar Wheel Bearing Grease be used for the following step application. Other lubricants may cause sensor failure. 1. Lubricate the sensor O-ring with Mopar Wheel Bearing Grease before installation into the Hub And Bearing. If not lubricated, an improper seal may result due to rolling of the O-ring. 2. If metal sensor retaining clip is not in the neutral installed position on hub and bearing cap, install from the bottom, if necessary, and push clip upward until it snaps into position. 3. Install wheel speed sensor head into rear of hub and bearing aligning index tab with the notch in the top of the mounting hole. Push the sensor in until it snaps into place on the metal retaining clip. 4. Install secondary (yellow) retaining clip over wheel speed sensor head and engage the tabs on each side. 5. Route sensor cable under leaf spring along rear of axle. Install speed sensor cable into routing clips on rear brake flex hose (Fig. 3). 6. Install cable into metal routing clip and attach it to the rear axle with mounting bolt (Fig. 3). Tighten mounting bolt to 16 Nm (140 inch lbs.). 7. Connect wheel speed sensor cable to vehicle wiring harness (Fig. 2). Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector. 8. Install speed sensor cable grommet into hole in floor pan making sure grommet is fully seated into hole. 9. Lower vehicle. 10. Road test vehicle to ensure proper operation of the base and ABS braking systems. Rear Wheel Speed Sensor - AWD REAR WHEEL SPEED SENSOR - AWD REMOVAL 1. Raise vehicle. CAUTION: When disconnecting speed sensor cable from vehicle wiring harness be careful not to damage pins on the electrical connectors. Also, inspect connectors for any signs of previous damage. 2. Remove grommet from floor pan of vehicle and disconnect speed sensor cable connector from vehicle wiring harness. CAUTION: When removing rear wheel speed sensor cable from routing clips, be sure not to damage the routing clips. Routing clips that are molded onto the brake hose will require replacement of the brake hose if damaged during removal or installation of the speed sensor cable. 3. Carefully remove speed sensor cable from press-in routing clips along brake hose and tubing. 4. Remove bolt securing wheel speed sensor cable metal clip to rear of axle. Remove metal clip from cable if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Front > Page 6259 CAUTION: If speed sensor head has seized due to corrosion, do not use pliers on speed sensor head in an attempt to remove it. Use a hammer and a punch and tap mounting flange edge side-to-side, rocking the sensor until free. 5. Remove wheel speed sensor head attaching bolt. 6. Remove wheel speed sensor head from the axle, and remove sensor from vehicle. INSTALLATION CAUTION: Proper installation of wheel speed sensor cables is critical to continued system operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as indicated may result in contact with moving parts or over-extension of cables, resulting in an open circuit. 1. Install wheel speed sensor head in axle flange. CAUTION: Prior to installing the speed sensor head attaching bolt, the plastic anti-rotation pin must be fully seated into the bearing flange. 2. Install wheel speed sensor head attaching bolt. Tighten bolt to a torque 10 Nm (90 inch lbs.). 3. Check the air gap between the face of the wheel speed sensor and the top surface of the tone wheel. CAUTION: When installing wheel speed sensor cable in the routing clips on rear brake flex hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will require replacement of the brake hose if damaged. 4. Install speed sensor cable under leaf spring onto brake hose and tubing utilizing routing clips to secure it in place. 5. Install metal routing clip on speed sensor cable and mount it to rear of axle with mounting bolt. Tighten mounting bolt to 16 Nm (140 inch lbs.). 6. Connect wheel speed sensor cable to vehicle wiring harness. Be sure speed sensor cable connector is fully seated and locked into vehicle wiring harness connector. 7. Install speed sensor cable grommet into the floor pan, being sure the grommet is fully seated into the access hole. 8. Lower vehicle. 9. Road test vehicle to ensure proper operation of the base and ABS braking systems. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Specifications Specifications - Battery Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Specifications > Page 6265 Battery Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Specifications > Page 6266 Battery Temperature Sensor: Description and Operation (NGC Vehicles) The PCM incorporates a Battery Temperature Sensor (BTS) on its circuit board. The PCM uses the temperature of the battery area to control the charge system voltage. This temperature, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as temperature around the battery increases. For vehicles with 1.6L engine, there is no physical battery temp sensor in place to detect battery temp. Rather, an algorithm built in PCM is employed to predict battery temp using inlet air temp, vehicle speed, and coolant temp, among other signals. The PCM maintains the optimal output of the generator by monitoring battery voltage and controlling it to a range of 13.5 - 14.7 volts based on battery temperature. The system target voltage is 13.5 - 14.7 volts. However the actual voltage go below this during heavy electrical loads and generator speeds. Also the actual voltage can be lower than the target voltage between the battery and the battery voltage sense circuit, approximately 0.2 - 0.3 volts. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20°F. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature Sensor > Component Information > Specifications > Page 6267 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor is not serviced separately. If replacement is necessary, the PCM must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Right Side Kick Panel RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation KEY/LOCK CYLINDER DESCRIPTION The lock cylinder is inserted in the end of the housing opposite the ignition switch. OPERATION The ignition key rotates the cylinder to 5 different detents (Fig. 30): Accessory - Off (lock) - Unlock - On/Run - Start Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 6275 Ignition Switch Lock Cylinder: Service and Repair Key/Lock Cylinder REMOVAL 1. Disconnect negative cable from battery. 2. Remove steering column cover retaining screws. 3. Remove screws holding steering column shrouds and remove lower shroud. 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab on the bottom of the lock housing and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position (Fig. 31). 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6. Install steering column cover. 7. Connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 6280 Starter Relay: Diagrams 8w-10-3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 6281 8w-10-5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 6282 Starter Motor Relay Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation Battery Cable: Description and Operation The battery cables are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high electrical current carrying capacity. A clamping type female battery terminal made of stamped metal is attached to one end of the battery cable wire. A square headed pinch-bolt and hex nut are installed at the open end of the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and then solder-dipped. The battery positive cable wires have a red insulating jacket to provide visual identification and feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires have a black insulating jacket and a smaller female battery terminal clamp. The battery cables cannot be repaired and, if damaged or faulty they must be replaced. Both the battery positive and negative cables are available for service replacement only as a unit with the battery wire harness, which may include portions of the wiring circuits for the generator and other components on some vehicles. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also provide a path back to the battery for electrical current generated by the charging system for restoring the voltage potential of the battery. The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable connection of the battery cable to the battery terminal posts. The terminal pinch bolts allow the female terminal clamps to be tightened around the male terminal posts on the top of the battery. The eyelet terminals secured to the opposite ends of the battery cable wires from the female battery terminal clamps provide secure and reliable connection of the battery cables to the vehicle electrical system. The battery positive cable terminal clamp is attached to the ends of two wires. One wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the Integrated Power Module (IPM), and the other wire has an eyelet terminal that connects the battery positive cable to the B(+) terminal stud of the engine starter motor solenoid. The battery negative cable terminal clamp is also attached to the ends of two wires. One wire has an eyelet terminal that connects the battery negative cable to the vehicle powertrain through a stud on the left side of the engine cylinder block. The other wire has an eyelet terminal that connects the battery negative cable to the vehicle body through a ground screw on the left front fender inner shield, near the battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 6287 Battery Cable: Testing and Inspection A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cable. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair. When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable. VOLTAGE DROP TEST The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing this test, be certain that the following procedures are accomplished: - The battery is fully-charged and load tested. - Fully engage the parking brake. - If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the Park position. If the vehicle is equipped with a transmission, place the gearshift selector lever in the Neutral position and block the clutch pedal in the fully depressed position. - Verify that all lamps and accessories are turned off. - To prevent the engine from starting, remove the Automatic Shut Down (ASD) relay. The ASD relay is located in the Intelligent Power Module (IPM), in the engine compartment. See the fuse and relay layout label affixed to the underside of the IPM cover for ASD relay identification and location. Test Battery Negative Connection Resistance - Typical 1. Connect the positive lead of the voltmeter to the battery negative terminal post. Connect the negative lead of the voltmeter to the battery negative cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 6288 Test Battery Positive Connection Resistance - Typical 2. Connect the positive lead of the voltmeter to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post. Test Battery Positive Cable Resistance - Typical 3. Connect the voltmeter to measure between the battery positive cable terminal clamp and the starter solenoid B(+) terminal stud. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid B(+) terminal stud. Repeat the test. If the reading is still above 0.2 volt, replace the inoperative battery positive cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 6289 Test Ground Circuit Resistance - Typical 4. Connect the voltmeter to measure between the battery negative cable terminal clamp and a good clean ground on the engine block. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the inoperative battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 6290 Battery Cable: Service and Repair REMOVAL The battery cables on this vehicle may include portions of wiring circuits for the generator and other components on the vehicle. If battery cable replacement is required, it will be necessary to extract the cables out of the engine wire harness assembly. Use care not to damage the other wires and circuits which are also packaged into the engine wire harness assembly. 1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. 2. Disconnect and isolate the battery negative cable. 3. Remove the battery thermowrap (if equipped) from the battery tray. 4. Remove the tape from the engine wire harness assembly, to access the desired battery cable. 5. One at a time, trace and disconnect the battery cable retaining fasteners and routing clips until the desired cable is free from the vehicle. 6. Feed the battery cable out of the vehicle. INSTALLATION 1. Position the battery cable in the vehicle. 2. One at a time, trace and install the battery cable retaining fasteners and routing clips until the desired cable is properly installed in the engine wire harness assembly. 3. Install the tape on the engine wire harness assembly. 4. Install the battery thermowrap (if equipped) on the battery tray. 5. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Specifications Specifications - Battery Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Specifications > Page 6294 Battery Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Specifications > Page 6295 Battery Temperature Sensor: Description and Operation (NGC Vehicles) The PCM incorporates a Battery Temperature Sensor (BTS) on its circuit board. The PCM uses the temperature of the battery area to control the charge system voltage. This temperature, along with data from monitored line voltage, is used by the PCM to vary the battery charging rate. The system voltage is higher at cold temperatures and is gradually reduced as temperature around the battery increases. For vehicles with 1.6L engine, there is no physical battery temp sensor in place to detect battery temp. Rather, an algorithm built in PCM is employed to predict battery temp using inlet air temp, vehicle speed, and coolant temp, among other signals. The PCM maintains the optimal output of the generator by monitoring battery voltage and controlling it to a range of 13.5 - 14.7 volts based on battery temperature. The system target voltage is 13.5 - 14.7 volts. However the actual voltage go below this during heavy electrical loads and generator speeds. Also the actual voltage can be lower than the target voltage between the battery and the battery voltage sense circuit, approximately 0.2 - 0.3 volts. The battery temperature sensor is also used for OBD II diagnostics. Certain faults and OBD II monitors are either enabled or disabled depending upon the battery temperature sensor input (example: disable purge and EGR, enable LDP). Most OBD II monitors are disabled below 20°F. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information > Specifications > Page 6296 Battery Temperature Sensor: Service and Repair REMOVAL The battery temperature sensor is not serviced separately. If replacement is necessary, the PCM must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown Battery Tray: Service and Repair Battery Holddown REMOVAL All of the battery hold down hardware can be serviced without removal of the battery or the battery tray and support unit. 1. Turn the ignition switch to the Off position. Be certain that all electrical accessories are turned off. 2. Disconnect and isolate the battery negative cable. 3. Remove the nut with washer that secures the battery hold down bracket to the battery tray and support unit. 4. Remove the battery hold down bracket from the battery tray and support unit. INSTALLATION 1. Install the battery hold down bracket in the battery tray and support unit. 2. Install the nut with washer that secures the battery hold down bracket to the battery tray and support unit. Torque to 20 N.m (180 in. lbs.). 3. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 6301 Battery Tray: Service and Repair Battery Tray REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect and isolate the battery positive cable. 3. Remove the battery from the vehicle. Battery Tray Position & Orientation 4. Remove the battery tray retaining fasteners. 5. Pull battery tray up far enough to disconnect the engine vacuum harness hose from the battery tray mounted, vacuum reservoir. 6. Remove the battery tray from the vehicle. INSTALLATION 1. Position the battery tray in the vehicle. 2. Connect the engine vacuum harness hose on the battery tray mounted vacuum reservoir. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Holddown > Page 6302 Battery Tray Position & Orientation 3. Position drainage hose and install the battery tray retaining fasteners. 4. Install the battery in the vehicle. 5. Connect the battery positive cable. 6. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Description and Operation Alternator Pulley: Description and Operation Generator Decoupler 3.3/3.8L The Generator Decoupler is a one way clutch. It is attached to the generator and replaces the standard pulley. It is a non-serviceable item and is to be replaced as an assembly. It is a dry operation (no grease or lubricants). The operation of it is not temperature sensitive and has a low sensitivity to electrical load. The generator decoupler is a one way clutch and should be replaced as an assembly. It is designed to help reduce belt tension fluctuation, reduce fatigue loads, improve belt life, reduce hub loads on components, and reduce noise. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Description and Operation > Page 6308 Diagnosis And Testing - Generator Decoupler Pulley Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Description and Operation > Page 6309 Alternator Pulley: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. Disconnect battery negative cable. 3. Raise vehicle and support. 4. Remove the right front lower splash shield. Drive Belt 3.3/3.8L 5. Remove accessory drive belt. 6. Lower vehicle. 7. Remove the Air Box. 8. Remove the decoupler pulley cover. Decoupler Removal (LITENS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Description and Operation > Page 6310 Special Tool 8433 And Decoupler 9. Use Special Tool #8433 to loosen the Generator Decoupler. 10. Remove the tool. 11. Remove the Generator Decoupler. INSTALLATION 1. Install the Generator Decoupler to the generator shaft. Decoupler Installation 2. Use Special Tool #8433 to tighten the Generator Decoupler. Refer to the torque chart for the proper torque. 3. Install a new decoupler pulley cover. 4. Install the Air Box. 5. Raise vehicle and support. 6. Install accessory drive belt. 7. Install the right front lower splash shield. 8. Lower vehicle. 9. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation Voltage Regulator: Description and Operation The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground. Voltage is regulated within the PCM on the NGC vehicles, to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage at the PDC and calculated battery temperature or inlet air temperature sensor. It then determines a target charging voltage. If sensed battery voltage is lower than the target voltage, the PCM feeds the field winding until sensed battery voltage is at the target voltage. A circuit in the PCM cycles the feed side of the generator field at 250 times per second (250Hz), but has the capability to feed the field control wire 100% of the time (full field) to achieve the target voltage. If the charging rate cannot be monitored (limp-in), a duty cycle of 20% is used by the PCM in order to have some generator output. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations Right Side Kick Panel RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation Ignition Switch Lock Cylinder: Description and Operation KEY/LOCK CYLINDER DESCRIPTION The lock cylinder is inserted in the end of the housing opposite the ignition switch. OPERATION The ignition key rotates the cylinder to 5 different detents (Fig. 30): Accessory - Off (lock) - Unlock - On/Run - Start Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Description and Operation > Page 6322 Ignition Switch Lock Cylinder: Service and Repair Key/Lock Cylinder REMOVAL 1. Disconnect negative cable from battery. 2. Remove steering column cover retaining screws. 3. Remove screws holding steering column shrouds and remove lower shroud. 4. Place key cylinder in RUN position. Depress lock cylinder retaining tab on the bottom of the lock housing and remove key cylinder. INSTALLATION 1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed). 2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align the socket with the lock cylinder, ensure the socket is in the Run position (Fig. 31). 3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing until the tab sticks through the opening in the housing. 4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6. Install steering column cover. 7. Connect negative cable to battery. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations Starter Motor: Locations Starter Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 6326 3.3-3.8 Liter Engine Front Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 6327 Starter Motor: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate the battery negative cable. 3. Hoist and support vehicle on safety stands. Starter 4. Remove nut holding B+ terminal to starter solenoid. 5. Disconnect solenoid connector from starter. Starter Bolts 6. Remove bolts holding starter to transaxle bellhousing. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Locations > Page 6328 Starter 3.3L/3.8L 7. Remove starter from bellhousing. 8. Separate starter spacer from transaxle bellhousing. INSTALLATION 1. Place starter spacer in position on transaxle bellhousing, flange toward flywheel. 2. Place starter in position on bellhousing. 3. Install bolts and ground wire to hold starter to transaxle bellhousing. 4. Connect solenoid connector into starter. 5. Install nut to hold B+ terminal to starter solenoid. 6. Lower vehicle. 7. Connect battery negative cable. 8. Verify starter operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 6332 Starter Relay: Diagrams 8w-10-3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 6333 8w-10-5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 6334 Starter Motor Relay Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6340 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6341 Figure 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6342 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6343 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6344 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6345 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6346 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6347 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6348 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6349 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6350 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6351 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6352 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6353 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6354 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6355 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6356 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and an Electrostatic Discharge Symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6357 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6358 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6359 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6360 Auxiliary Power Outlet: Connector Views Floor Console Power Outlet (Export) Power Outlet (Except Lowline) Rear Power Outlet Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6361 Auxiliary Power Outlet: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-41-2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6362 8w-41-3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6363 8w-41-4 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6364 Auxiliary Power Outlet: Description and Operation Two power outlets are installed in the instrument panel center lower bezel. Two additional power outlets are incorporated into the left rear C-pillar and the center console (if equipped). The power outlets bases are secured by a snap fit. A hinged plug flips closed to conceal and protect the power outlet base when not in use. The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet on the instrument panel marked with a battery receives battery voltage from a fuse in the Integrated Power Module (IPM) at all times. The other power outlet on the instrument panel marked with a key receives battery voltage only when the key is in the on position. key is in the on position. The power outlet located in the center console receives battery voltage all the time when positioned between the front seats and key-on voltage when positioned between the rear seats. The power outlet located on the C-pillar receives battery voltage only when the key is in the ON position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6365 Auxiliary Power Outlet: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fused B(+) fuse in the Integrated Power Module (IPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse in the IPM. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. 3. Open the power outlet door. Check for continuity between the inside circumference of the power outlet receptacle and a good ground. There should be continuity. If OK, go to Step 4. If not OK, go to Step 5. 4. Check for battery voltage at the insulated contact located at the back of the power outlet receptacle. If not OK, go to Step 5. 5. Disconnect and isolate the battery negative cable. Remove the appropriate bezel. Check for continuity between the ground circuit cavity of the power outlet wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power outlet wire harness connector. If OK, replace the faulty power outlet receptacle. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6366 Auxiliary Power Outlet: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Outlet 2. Note position of the retaining bosses. 3. Using external snap ring pliers with 90 degree tips. Insert pliers with tips against bosses and squeeze forcing bosses out of base. 4. Pull out the base through mounting ring by gently rocking pliers. 5. Disconnect the base wires. 6. Remove light ring and disconnect wire. INSTALLATION 1. Position the mounting ring on the instrument panel and feed the wires through the ring. Index the cap and the mounting ring with the index tab at the 9 O'clock position to the key in the instrument panel. Install the ring. 2. Connect the wires to the base. Orientate the base alignment rib at the 11 O'clock position to mate the groove in the mounting ring to the base. 3. Push the base into the bezel until it locks in place. 4. Check operation of outlet or element and install the outlet cap. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 6370 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 6371 Power Seat Circuit Breaker (30A) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations Left Side Engine Compartment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 6375 Electrical Accessory Panel: Diagrams Integrated Power Module C1 Integrated Power Module C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 6376 Integrated Power Module C3 Integrated Power Module C4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 6377 Integrated Power Module C5 Integrated Power Module C6 Integrated Power Module C7 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 6378 Integrated Power Module C8 Integrated Power Module C9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 6379 Electrical Accessory Panel: Description and Operation Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) and the Front Control Module (FCM). The IPM is located in the engine compartment, next to the battery.The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. This IPM connects directly to the battery positive through a four pin connector. The ground connection is through two other connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. All of the current from the battery and the generator output enters the Integrated Power Module (IPM) through a four pin connector on the bottom of the module. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 6380 Electrical Accessory Panel: Service and Repair REMOVAL 1. Disconnect the negative and positive battery cables. 2. Remove the battery thermal guard. 3. Remove the battery. Integrated Power Module 4. Using a flat-bladed screwdriver, twist the Integrated Power Module (IPM) bracket retaining latch outward to free the IPM from its mounting bracket Disconnecting IPM 5. Rotate the IPM counter-clockwise to access and disconnect the electrical connectors. INSTALLATION 1. Snap the left side of the Integrated Power Module (IPM) housing in its mounting bracket and connect the various electrical connectors. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 6381 NOTE: Ensure that the Connector Positive Assurance (CPA) on the five-pin B+ connector is positively engaged to prevent generating a Diagnostic Trouble Code (DTC). 2. Rotate the IPM clock-wise until secured in mounting bracket. An audible click may be heard. 3. Install the battery. 4. Install the battery thermal guard. 5. Connect the negative and positive battery cables. 6. Using a scan tool, check for any stored diagnostic trouble codes. Ensure that all vehicle options are operational. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6386 Fuse: Locations Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6387 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6388 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6389 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6390 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6391 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6392 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6393 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6394 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6395 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6398 Fuse: Application and ID Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6399 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6400 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6401 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6402 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6403 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6404 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6405 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6406 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6407 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6412 Fuse Block: Locations Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6413 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6414 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6415 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6416 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6417 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6418 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6419 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6420 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6421 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6426 Fuse Block: Application and ID Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6427 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6428 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6429 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6430 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6431 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6432 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6433 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6434 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6435 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component Locations > Page 6440 Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 6441 Front Control Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) and the Front Control Module (FCM). The IPM is located in the engine compartment, next to the battery.The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. This IPM connects directly to the battery positive through a four pin connector. The ground connection is through two other connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. All of the current from the battery and the generator output enters the Integrated Power Module (IPM) through a four pin connector on the bottom of the module. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 6444 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is an electrical control and interface center located in the engine compartment. When it is mated to the Power Distribution Center (PDC), it is referred to as the Integrated Power Module (IPM). The IPM, with its fuses and relays provides power and signal distribution throughout most of the vehicle. The FCM receives both hard wire and digital electronic inputs from the vehicle electrical system through the PDC. Based on these inputs and the ignition switch position, it provides direct power feeds and relay control to some of the vehicles most critical electrical systems. The Front Control Module provides the following features: Controlled power feeds: - Front airbag system - Headlamp power - EATX module power (4 speed only) - Front washer motor - Rear washer motor - Cabin Heater - Brake shift interlock system Relay controls: - Fog lamp relay (when equipped) - Park lamp relay - Front wiper on relay - Front wiper high/low relay - Accessory relay - Horn relay - Front & rear blower relay - Name brand speakers (NBS) relay - Adjustable pedals relay (non-memory) - Electronic back light (EBL) run only relay Electrical inputs: - Headlamp battery supplies 1 & 2 - Module battery supply - Power ground - Ignition switch RUN or START position status - Ignition switch START only status - PCI Bus - Stop lamp switch - Horn switch - Back-up switch - Wiper park switch - Washer fluid level switch - Brake fluid level switch - Ambient temperature sensor - Right park lamp outage - Left park lamp outage - Battery IOD - Battery (+) connection detection - Flash reprogramming voltage CONTROLLED POWER FEEDS Front airbag system The FCM provides power to the Occupant Restraint Control (ORC) system through two fuseless circuits (ORC RUN/START, and ORC RUN only). These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied while the ignition switch is in the RUN and START positions on pin 48 of the FCM connector, and in the RUN only position on pin 29. Headlamp power The headlamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a headlamp switch status change. The FCM then turns on power to the headlamps through four fuseless circuits. These circuits are electronically controlled and continuously monitored for malfunctions.Power is supplied to each filament in a separate circuit. For vehicles equipped with Daytime Running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination. EATX power The electronic automatic 4 speed transmission module is powered when the ignition switch is in the UNLOCK, RUN or START positions. This circuit is Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 6445 electronically controlled and continuously monitored for malfunctions. Power is supplied through pin 27 of the FCM connector. Front washer motor The front washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The front washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition, the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Rear washer motor The rear washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The rear washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition,the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Cabin Heater When the ignition is in Run, the FCM monitors the PCI bus for the Cabin Heater Activation request. The Automatic or Manual Temperature Control initiates this request only when all conditions for the Cabin Heater activation are favorable. The request carries the status bit that the FCM requires to activate its Cabin Heater Assist Control output. This output is a low side driver (coming from FCM pin 15) which supplies a ground signal to the Cabin Heater (pin 5). When the Cabin Heater receives this ground signal input, it interprets this as an activation signal. The FCM low side driver is also capable of diagnostic sensing. The driver will sense an open circuit when the driver is off, and will sense a short to voltage when the driver is on. The FCM will set DTC's for both of these types of faults. For additional information, refer to Cabin Heater under General Information and Diagnostic Procedures. Brake shift interlock system The brake shift interlock solenoid receives power from both high side and low side controls inside the FCM. The high side control is on the same circuit as the EATX module power, and the low side control comes through pin 47 of the FCM connector. The solenoid is controlled by the low side driver when the brake pedal is pressed. Both circuits are continuously monitored for malfunctions. RELAY CONTROLS Fog lamp relay The fog lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the fog lamp relay. The fog lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Fog lamp functionality is not equipped on all vehicles. The FCM learns that the vehicle is equipped with fog lamps by reading the BCM PCI Bus message. Park lamp relay The park lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the park lamp relay. The park lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper on relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper on relay. The front wiper on relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper high/low relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper high/ low relay. The relay switches power between the low speed and high speed windings of the wiper motor. The front wiper high/low relay is powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Accessory relay The accessory relay works in conjunction with the FCM's power accessory delay feature to control the operation of the radio, power windows, washer motors,wiper motors and power outlet. The accessory relay is turned on through low side control on pin 35 of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Depending on the ignition switch position, the accessory relay will remain on or will time-out and turn off. The accessory relay remains on in the RUN and ACCY positions of the ignition switch. In the UNLK and OFF positions, the relay will remain energized for 45 seconds then turn off. During this time-out period, if the driver or passenger doors are opened, the relay will turn off immediately. While the ignition switch is in the START position, the relay will also drop-out, then resume operation. Accessory relay operation is most Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 6446 noticeable by observing the operation of the radio or blower functions. Horn relay The horn relay operates through a direct wire input to the FCM from the horn switch (FCM pin 17) , or a PCI Bus message from the BCM. The relay responds to the horn switch, remote door lock and VTA alarm functions. The horn relay is powered through low side control on pin 10 of the FCM. Under normal operating conditions, if the horn is pressed for longer than 30 seconds, the FCM will automatically deactivate the horn to prevent damage to it. The FCM will re-activate control of the relay after a 25 second cool-down period. This circuit is electronically controlled and continuously monitored for malfunctions. Front and rear blower relay RS with MTC Upon ignition on, the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus.The front blower relay and the rear blower relay, if equipped, are then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. RG with MTC Upon power up (Power switch on), the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus. The front blower relay is then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. Name Brand Speakers (NBS) relay The NBS relay operates through the vehicle bus interface between the radio and the FCM. When the radio is turned on, the radio sends a PCI Bus message to the FCM. The NBS relay is then powered on through low side control on pin 11 of the FCM. The relay supplies power to the amplified speaker, and ground is supplied through the radio. This circuit is electronically controlled and continuously monitored for malfunctions. Electronic Back Light (EBL) relay The rear defrost switch is part of the Automatic Temperature Control or A/C-Heater Control Module (Manual Temp). When the ignition switch is in the RUN position and the rear defrost switch is turned on, the ATC or A/C-Heater Control Module sends a PCI Bus message to the FCM. The EBL run only relay is then powered through low side control on pin 31 of the FCM. The relay provides the high side to the rear window defrost grid, and ground is attached to the vehicle body. The FCM will only allow the rear defrost to operate in the RUN position. This circuit is electronically controlled and continuously monitored for malfunctions. Adjustable Pedals Relay (Non-Memory) The Adjustable Pedals Relay is only on nonmemory Adjustable Pedals System equipped vehicles. The relay is supplied battery voltage from the IPM and is electronically controlled with a low side driver within the FCM. The relay is energized when the transmission is in reverse and when cruise control operation is engaged. This action disables the Adjustable Pedals System from movement. This circuit is continuously monitored for proper function. ELECTRICAL INPUTS Headlamp battery supplies 1 & 2 - 12 volt input on pins 1 and 2. Battery supply voltage for switching headlamp circuits only. Module battery supply - 12 volt input on pin 9. Battery supply voltage for all other FCM operations. Power ground - Ground source on pin 8 for all FCM operations. Ignition switch RUN or START position status - 12 volt input on pin 37. Allows the FCM to determine the ignition switch status for related FCM operations. PCI Bus - Approximately 7.5 volt input on pin 22. Allows the FCM to communicate with other modules on the vehicle bus. Stop lamp Switch status - 12 volt input on pin 44. Provides for brake shift interlock function. Horn Switch - Ground input on pin 17. Primary means for engaging the horn. Back-up switch - Ground input on pin 39. Input is converted to a PCI Bus status message for use by other modules. Wiper park switch - Ground input on pin 16. Used to determine park placement of wipers. Also used as feedback to FCM to determine correct operating mode of wipers. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 6447 Washer fluid level switch - Ground input to pull-up on pin 18. Ground is switched into the circuit when washer bottle fluid level is low. Brake fluid level switch - Ground input to pull-up on pin 36. Ground is switched into the circuit when brake fluid level is low. Ambient temperature sensor - Resistive input to pull-up on pin 25. Corresponding voltage level is converted to a PCI Bus message for use by other modules on the bus. Right park lamp outage - 12 volt input on pin 21. Used to determine if right park lamp circuit is operating properly. Left park lamp outage - 12 volt input on pin 41. Used to determine if left park lamp circuit is operating properly. Battery IOD - 12 volt input on pin 20. The FCM enters a low power consumption mode when the ignition is turned OFF. This low current draw battery supply keeps the microprocessor functioning in the low power mode. Battery (+) connection detection - 12 volt input on pin 38. The battery connection on the PDC incorporates the use of an internal switch to determine if the connector is properly mated and the Connector Positive Assurance (CPA) is engaged. If the CPA is not properly engaged, a voltage on pin 38 will be interpreted as an unseated connector and a fault will set. Flash programming voltage - 20 volt input on pin 42. When a DRBIII(R) is connected and the proper flash reprogramming sequence is selected, the 20 volt signal will be applied through pin 42. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 6448 Power Distribution Module: Testing and Inspection The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any front control module related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool, such as the DRB III(R). The most reliable, efficient, and accurate means to diagnose the front control module requires the use of a DRB III(R) scan tool and the proper Body Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. For information regarding Trouble Code Diagnostic Charts for this system, please refer to Body Control Module testing. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect the negative and positive battery cables. 2. Remove the battery thermal guard. 3. Remove the battery. Integrated Power Module 4. Using a flat-bladed screwdriver, twist the Integrated Power Module (IPM) bracket retaining latch outward to free the IPM from its mounting bracket Disconnecting IPM 5. Rotate the IPM counter-clockwise to access and disconnect the electrical connectors. 6. Remove the IPM bracket clips from the hinge. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 6451 1. Snap the left side of the Integrated Power Module (IPM) housing in its mounting bracket and connect the various electrical connectors. NOTE: Ensure that the Connector Positive Assurance (CPA) on the five-pin B+ connector is positively engaged to prevent generating a Diagnostic Trouble Code (DTC). 2. Rotate the IPM clock-wise until secured in mounting bracket. An audible click may be heard. 3. Install the battery. 4. Install the battery thermal guard. 5. Connect the negative and positive battery cables. 6. Using a scan tool, check for any stored diagnostic trouble codes. Ensure that all vehicle options are operational. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 6452 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the negative and positive battery cables from the battery. 2. Remove the battery. Removing Integrated Power Module 3. Using a long flat-bladed screwdriver, gently twist the Integrated Power Module (IPM) retaining clip outboard to free the IPM from its mounting bracket. Rotate IPM upward to access the Front Control Module (FCM) retaining screws. 4. Remove the front control module retaining screws. Front Control Module 5. Pull the FCM straight from the IPM assembly to disconnect the electrical connector and remove the FCM from the vehicle. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 6453 NOTE: Front Control Module must be programmed to the correct radio EQ curve using the DRB III(R). This will ensure that the audio system is operating correctly. 1. Install the Front Control Module (FCM) in the Integrated Power Module (IPM) assembly by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 1 N.m (7 in. lbs). 3. Rotate the IPM assembly downward to secure in mounting bracket. 4. Install the battery in the vehicle. 5. Connect the positive and negative battery cables. 6. Using the DRB III(R), under "FRONT CONTROL MODULE" then "MISC" program the EQ curve of the radio into the Front Control Module. NOTE: If the vehicle is not equipped with Name Brand Speakers (Infinity, etc.) or Headlamp Washers the DRB IIIT must be used to Disable the appropriate relays in the Integrated Power Module Assembly Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is removed from its normal cavity in the Integrated Power Module (IPM) when the vehicle is shipped from the factory. Dealer personnel are to remove the IOD fuse from the storage location and install it into the IPM fuse cavity marked IOD as part of the preparation procedures performed just prior to new vehicle delivery. The IOD fuse is a 20 ampere blade-type mini fuse and, when removed, it is stored in a fuse cavity adjacent to the washer fuse within the IPM. The term ignition-off draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position, including the clock. The only reason the IOD fuse is removed is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is removed from the Integrated Power Module (IPM) fuse cavity when the vehicle is shipped from the assembly plant. Dealer personnel must install the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed approximately thirty days. However, it must be remembered that removing the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component Locations > Page 6462 Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 6463 Front Control Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) and the Front Control Module (FCM). The IPM is located in the engine compartment, next to the battery.The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. This IPM connects directly to the battery positive through a four pin connector. The ground connection is through two other connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. All of the current from the battery and the generator output enters the Integrated Power Module (IPM) through a four pin connector on the bottom of the module. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 6466 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is an electrical control and interface center located in the engine compartment. When it is mated to the Power Distribution Center (PDC), it is referred to as the Integrated Power Module (IPM). The IPM, with its fuses and relays provides power and signal distribution throughout most of the vehicle. The FCM receives both hard wire and digital electronic inputs from the vehicle electrical system through the PDC. Based on these inputs and the ignition switch position, it provides direct power feeds and relay control to some of the vehicles most critical electrical systems. The Front Control Module provides the following features: Controlled power feeds: - Front airbag system - Headlamp power - EATX module power (4 speed only) - Front washer motor - Rear washer motor - Cabin Heater - Brake shift interlock system Relay controls: - Fog lamp relay (when equipped) - Park lamp relay - Front wiper on relay - Front wiper high/low relay - Accessory relay - Horn relay - Front & rear blower relay - Name brand speakers (NBS) relay - Adjustable pedals relay (non-memory) - Electronic back light (EBL) run only relay Electrical inputs: - Headlamp battery supplies 1 & 2 - Module battery supply - Power ground - Ignition switch RUN or START position status - Ignition switch START only status - PCI Bus - Stop lamp switch - Horn switch - Back-up switch - Wiper park switch - Washer fluid level switch - Brake fluid level switch - Ambient temperature sensor - Right park lamp outage - Left park lamp outage - Battery IOD - Battery (+) connection detection - Flash reprogramming voltage CONTROLLED POWER FEEDS Front airbag system The FCM provides power to the Occupant Restraint Control (ORC) system through two fuseless circuits (ORC RUN/START, and ORC RUN only). These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied while the ignition switch is in the RUN and START positions on pin 48 of the FCM connector, and in the RUN only position on pin 29. Headlamp power The headlamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a headlamp switch status change. The FCM then turns on power to the headlamps through four fuseless circuits. These circuits are electronically controlled and continuously monitored for malfunctions.Power is supplied to each filament in a separate circuit. For vehicles equipped with Daytime Running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination. EATX power The electronic automatic 4 speed transmission module is powered when the ignition switch is in the UNLOCK, RUN or START positions. This circuit is Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 6467 electronically controlled and continuously monitored for malfunctions. Power is supplied through pin 27 of the FCM connector. Front washer motor The front washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The front washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition, the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Rear washer motor The rear washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The rear washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition,the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Cabin Heater When the ignition is in Run, the FCM monitors the PCI bus for the Cabin Heater Activation request. The Automatic or Manual Temperature Control initiates this request only when all conditions for the Cabin Heater activation are favorable. The request carries the status bit that the FCM requires to activate its Cabin Heater Assist Control output. This output is a low side driver (coming from FCM pin 15) which supplies a ground signal to the Cabin Heater (pin 5). When the Cabin Heater receives this ground signal input, it interprets this as an activation signal. The FCM low side driver is also capable of diagnostic sensing. The driver will sense an open circuit when the driver is off, and will sense a short to voltage when the driver is on. The FCM will set DTC's for both of these types of faults. For additional information, refer to Cabin Heater under General Information and Diagnostic Procedures. Brake shift interlock system The brake shift interlock solenoid receives power from both high side and low side controls inside the FCM. The high side control is on the same circuit as the EATX module power, and the low side control comes through pin 47 of the FCM connector. The solenoid is controlled by the low side driver when the brake pedal is pressed. Both circuits are continuously monitored for malfunctions. RELAY CONTROLS Fog lamp relay The fog lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the fog lamp relay. The fog lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Fog lamp functionality is not equipped on all vehicles. The FCM learns that the vehicle is equipped with fog lamps by reading the BCM PCI Bus message. Park lamp relay The park lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the park lamp relay. The park lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper on relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper on relay. The front wiper on relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper high/low relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper high/ low relay. The relay switches power between the low speed and high speed windings of the wiper motor. The front wiper high/low relay is powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Accessory relay The accessory relay works in conjunction with the FCM's power accessory delay feature to control the operation of the radio, power windows, washer motors,wiper motors and power outlet. The accessory relay is turned on through low side control on pin 35 of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Depending on the ignition switch position, the accessory relay will remain on or will time-out and turn off. The accessory relay remains on in the RUN and ACCY positions of the ignition switch. In the UNLK and OFF positions, the relay will remain energized for 45 seconds then turn off. During this time-out period, if the driver or passenger doors are opened, the relay will turn off immediately. While the ignition switch is in the START position, the relay will also drop-out, then resume operation. Accessory relay operation is most Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 6468 noticeable by observing the operation of the radio or blower functions. Horn relay The horn relay operates through a direct wire input to the FCM from the horn switch (FCM pin 17) , or a PCI Bus message from the BCM. The relay responds to the horn switch, remote door lock and VTA alarm functions. The horn relay is powered through low side control on pin 10 of the FCM. Under normal operating conditions, if the horn is pressed for longer than 30 seconds, the FCM will automatically deactivate the horn to prevent damage to it. The FCM will re-activate control of the relay after a 25 second cool-down period. This circuit is electronically controlled and continuously monitored for malfunctions. Front and rear blower relay RS with MTC Upon ignition on, the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus.The front blower relay and the rear blower relay, if equipped, are then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. RG with MTC Upon power up (Power switch on), the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus. The front blower relay is then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. Name Brand Speakers (NBS) relay The NBS relay operates through the vehicle bus interface between the radio and the FCM. When the radio is turned on, the radio sends a PCI Bus message to the FCM. The NBS relay is then powered on through low side control on pin 11 of the FCM. The relay supplies power to the amplified speaker, and ground is supplied through the radio. This circuit is electronically controlled and continuously monitored for malfunctions. Electronic Back Light (EBL) relay The rear defrost switch is part of the Automatic Temperature Control or A/C-Heater Control Module (Manual Temp). When the ignition switch is in the RUN position and the rear defrost switch is turned on, the ATC or A/C-Heater Control Module sends a PCI Bus message to the FCM. The EBL run only relay is then powered through low side control on pin 31 of the FCM. The relay provides the high side to the rear window defrost grid, and ground is attached to the vehicle body. The FCM will only allow the rear defrost to operate in the RUN position. This circuit is electronically controlled and continuously monitored for malfunctions. Adjustable Pedals Relay (Non-Memory) The Adjustable Pedals Relay is only on nonmemory Adjustable Pedals System equipped vehicles. The relay is supplied battery voltage from the IPM and is electronically controlled with a low side driver within the FCM. The relay is energized when the transmission is in reverse and when cruise control operation is engaged. This action disables the Adjustable Pedals System from movement. This circuit is continuously monitored for proper function. ELECTRICAL INPUTS Headlamp battery supplies 1 & 2 - 12 volt input on pins 1 and 2. Battery supply voltage for switching headlamp circuits only. Module battery supply - 12 volt input on pin 9. Battery supply voltage for all other FCM operations. Power ground - Ground source on pin 8 for all FCM operations. Ignition switch RUN or START position status - 12 volt input on pin 37. Allows the FCM to determine the ignition switch status for related FCM operations. PCI Bus - Approximately 7.5 volt input on pin 22. Allows the FCM to communicate with other modules on the vehicle bus. Stop lamp Switch status - 12 volt input on pin 44. Provides for brake shift interlock function. Horn Switch - Ground input on pin 17. Primary means for engaging the horn. Back-up switch - Ground input on pin 39. Input is converted to a PCI Bus status message for use by other modules. Wiper park switch - Ground input on pin 16. Used to determine park placement of wipers. Also used as feedback to FCM to determine correct operating mode of wipers. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 6469 Washer fluid level switch - Ground input to pull-up on pin 18. Ground is switched into the circuit when washer bottle fluid level is low. Brake fluid level switch - Ground input to pull-up on pin 36. Ground is switched into the circuit when brake fluid level is low. Ambient temperature sensor - Resistive input to pull-up on pin 25. Corresponding voltage level is converted to a PCI Bus message for use by other modules on the bus. Right park lamp outage - 12 volt input on pin 21. Used to determine if right park lamp circuit is operating properly. Left park lamp outage - 12 volt input on pin 41. Used to determine if left park lamp circuit is operating properly. Battery IOD - 12 volt input on pin 20. The FCM enters a low power consumption mode when the ignition is turned OFF. This low current draw battery supply keeps the microprocessor functioning in the low power mode. Battery (+) connection detection - 12 volt input on pin 38. The battery connection on the PDC incorporates the use of an internal switch to determine if the connector is properly mated and the Connector Positive Assurance (CPA) is engaged. If the CPA is not properly engaged, a voltage on pin 38 will be interpreted as an unseated connector and a fault will set. Flash programming voltage - 20 volt input on pin 42. When a DRBIII(R) is connected and the proper flash reprogramming sequence is selected, the 20 volt signal will be applied through pin 42. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 6470 Power Distribution Module: Testing and Inspection The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any front control module related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool, such as the DRB III(R). The most reliable, efficient, and accurate means to diagnose the front control module requires the use of a DRB III(R) scan tool and the proper Body Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. For information regarding Trouble Code Diagnostic Charts for this system, please refer to Body Control Module testing. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect the negative and positive battery cables. 2. Remove the battery thermal guard. 3. Remove the battery. Integrated Power Module 4. Using a flat-bladed screwdriver, twist the Integrated Power Module (IPM) bracket retaining latch outward to free the IPM from its mounting bracket Disconnecting IPM 5. Rotate the IPM counter-clockwise to access and disconnect the electrical connectors. 6. Remove the IPM bracket clips from the hinge. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 6473 1. Snap the left side of the Integrated Power Module (IPM) housing in its mounting bracket and connect the various electrical connectors. NOTE: Ensure that the Connector Positive Assurance (CPA) on the five-pin B+ connector is positively engaged to prevent generating a Diagnostic Trouble Code (DTC). 2. Rotate the IPM clock-wise until secured in mounting bracket. An audible click may be heard. 3. Install the battery. 4. Install the battery thermal guard. 5. Connect the negative and positive battery cables. 6. Using a scan tool, check for any stored diagnostic trouble codes. Ensure that all vehicle options are operational. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 6474 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the negative and positive battery cables from the battery. 2. Remove the battery. Removing Integrated Power Module 3. Using a long flat-bladed screwdriver, gently twist the Integrated Power Module (IPM) retaining clip outboard to free the IPM from its mounting bracket. Rotate IPM upward to access the Front Control Module (FCM) retaining screws. 4. Remove the front control module retaining screws. Front Control Module 5. Pull the FCM straight from the IPM assembly to disconnect the electrical connector and remove the FCM from the vehicle. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 6475 NOTE: Front Control Module must be programmed to the correct radio EQ curve using the DRB III(R). This will ensure that the audio system is operating correctly. 1. Install the Front Control Module (FCM) in the Integrated Power Module (IPM) assembly by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 1 N.m (7 in. lbs). 3. Rotate the IPM assembly downward to secure in mounting bracket. 4. Install the battery in the vehicle. 5. Connect the positive and negative battery cables. 6. Using the DRB III(R), under "FRONT CONTROL MODULE" then "MISC" program the EQ curve of the radio into the Front Control Module. NOTE: If the vehicle is not equipped with Name Brand Speakers (Infinity, etc.) or Headlamp Washers the DRB IIIT must be used to Disable the appropriate relays in the Integrated Power Module Assembly Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6480 Relay Box: Locations Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6481 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6482 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6483 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6484 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6485 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6486 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6487 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6488 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6489 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6490 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6493 Relay Box: Application and ID Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6494 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6495 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6496 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6497 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6498 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6499 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6500 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6501 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6502 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6507 Relay Box: Locations Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6508 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6509 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6510 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6511 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6512 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6513 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6514 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6515 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6516 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6517 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6520 Relay Box: Application and ID Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6521 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6522 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6523 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6524 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6525 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6526 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6527 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6528 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6529 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is removed from its normal cavity in the Integrated Power Module (IPM) when the vehicle is shipped from the factory. Dealer personnel are to remove the IOD fuse from the storage location and install it into the IPM fuse cavity marked IOD as part of the preparation procedures performed just prior to new vehicle delivery. The IOD fuse is a 20 ampere blade-type mini fuse and, when removed, it is stored in a fuse cavity adjacent to the washer fuse within the IPM. The term ignition-off draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position, including the clock. The only reason the IOD fuse is removed is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is removed from the Integrated Power Module (IPM) fuse cavity when the vehicle is shipped from the assembly plant. Dealer personnel must install the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed approximately thirty days. However, it must be remembered that removing the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6539 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6540 Figure 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6541 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6542 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6543 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6544 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6545 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6546 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6547 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6548 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6549 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6550 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6551 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6552 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6553 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6554 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6555 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and an Electrostatic Discharge Symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6556 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6557 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6558 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6559 Auxiliary Power Outlet: Connector Views Floor Console Power Outlet (Export) Power Outlet (Except Lowline) Rear Power Outlet Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6560 Auxiliary Power Outlet: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-41-2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6561 8w-41-3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6562 8w-41-4 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6563 Auxiliary Power Outlet: Description and Operation Two power outlets are installed in the instrument panel center lower bezel. Two additional power outlets are incorporated into the left rear C-pillar and the center console (if equipped). The power outlets bases are secured by a snap fit. A hinged plug flips closed to conceal and protect the power outlet base when not in use. The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet on the instrument panel marked with a battery receives battery voltage from a fuse in the Integrated Power Module (IPM) at all times. The other power outlet on the instrument panel marked with a key receives battery voltage only when the key is in the on position. key is in the on position. The power outlet located in the center console receives battery voltage all the time when positioned between the front seats and key-on voltage when positioned between the rear seats. The power outlet located on the C-pillar receives battery voltage only when the key is in the ON position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6564 Auxiliary Power Outlet: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Check the fused B(+) fuse in the Integrated Power Module (IPM). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse in the IPM. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. 3. Open the power outlet door. Check for continuity between the inside circumference of the power outlet receptacle and a good ground. There should be continuity. If OK, go to Step 4. If not OK, go to Step 5. 4. Check for battery voltage at the insulated contact located at the back of the power outlet receptacle. If not OK, go to Step 5. 5. Disconnect and isolate the battery negative cable. Remove the appropriate bezel. Check for continuity between the ground circuit cavity of the power outlet wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power outlet wire harness connector. If OK, replace the faulty power outlet receptacle. If not OK, repair the open fused B(+) circuit to the IPM fuse as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6565 Auxiliary Power Outlet: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Outlet 2. Note position of the retaining bosses. 3. Using external snap ring pliers with 90 degree tips. Insert pliers with tips against bosses and squeeze forcing bosses out of base. 4. Pull out the base through mounting ring by gently rocking pliers. 5. Disconnect the base wires. 6. Remove light ring and disconnect wire. INSTALLATION 1. Position the mounting ring on the instrument panel and feed the wires through the ring. Index the cap and the mounting ring with the index tab at the 9 O'clock position to the key in the instrument panel. Install the ring. 2. Connect the wires to the base. Orientate the base alignment rib at the 11 O'clock position to mate the groove in the mounting ring to the base. 3. Push the base into the bezel until it locks in place. 4. Check operation of outlet or element and install the outlet cap. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 6569 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 6570 Power Seat Circuit Breaker (30A) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations Left Side Engine Compartment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 6574 Electrical Accessory Panel: Diagrams Integrated Power Module C1 Integrated Power Module C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 6575 Integrated Power Module C3 Integrated Power Module C4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 6576 Integrated Power Module C5 Integrated Power Module C6 Integrated Power Module C7 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 6577 Integrated Power Module C8 Integrated Power Module C9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 6578 Electrical Accessory Panel: Description and Operation Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) and the Front Control Module (FCM). The IPM is located in the engine compartment, next to the battery.The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. This IPM connects directly to the battery positive through a four pin connector. The ground connection is through two other connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. All of the current from the battery and the generator output enters the Integrated Power Module (IPM) through a four pin connector on the bottom of the module. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 6579 Electrical Accessory Panel: Service and Repair REMOVAL 1. Disconnect the negative and positive battery cables. 2. Remove the battery thermal guard. 3. Remove the battery. Integrated Power Module 4. Using a flat-bladed screwdriver, twist the Integrated Power Module (IPM) bracket retaining latch outward to free the IPM from its mounting bracket Disconnecting IPM 5. Rotate the IPM counter-clockwise to access and disconnect the electrical connectors. INSTALLATION 1. Snap the left side of the Integrated Power Module (IPM) housing in its mounting bracket and connect the various electrical connectors. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations > Page 6580 NOTE: Ensure that the Connector Positive Assurance (CPA) on the five-pin B+ connector is positively engaged to prevent generating a Diagnostic Trouble Code (DTC). 2. Rotate the IPM clock-wise until secured in mounting bracket. An audible click may be heard. 3. Install the battery. 4. Install the battery thermal guard. 5. Connect the negative and positive battery cables. 6. Using a scan tool, check for any stored diagnostic trouble codes. Ensure that all vehicle options are operational. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6585 Fuse: Locations Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6586 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6587 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6588 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6589 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6590 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6591 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6592 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6593 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuses Integrated Power Module > Page 6594 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6597 Fuse: Application and ID Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6598 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6599 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6600 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6601 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6602 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6603 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6604 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6605 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Fuses Integrated Power Module > Page 6606 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6611 Fuse Block: Locations Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6612 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6613 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6614 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6615 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6616 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6617 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6618 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6619 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuses Integrated Power Module > Page 6620 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6625 Fuse Block: Application and ID Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6626 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6627 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6628 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6629 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6630 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6631 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6632 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6633 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Fuses Integrated Power Module > Page 6634 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component Locations > Page 6639 Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 6640 Front Control Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) and the Front Control Module (FCM). The IPM is located in the engine compartment, next to the battery.The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. This IPM connects directly to the battery positive through a four pin connector. The ground connection is through two other connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. All of the current from the battery and the generator output enters the Integrated Power Module (IPM) through a four pin connector on the bottom of the module. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 6643 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is an electrical control and interface center located in the engine compartment. When it is mated to the Power Distribution Center (PDC), it is referred to as the Integrated Power Module (IPM). The IPM, with its fuses and relays provides power and signal distribution throughout most of the vehicle. The FCM receives both hard wire and digital electronic inputs from the vehicle electrical system through the PDC. Based on these inputs and the ignition switch position, it provides direct power feeds and relay control to some of the vehicles most critical electrical systems. The Front Control Module provides the following features: Controlled power feeds: - Front airbag system - Headlamp power - EATX module power (4 speed only) - Front washer motor - Rear washer motor - Cabin Heater - Brake shift interlock system Relay controls: - Fog lamp relay (when equipped) - Park lamp relay - Front wiper on relay - Front wiper high/low relay - Accessory relay - Horn relay - Front & rear blower relay - Name brand speakers (NBS) relay - Adjustable pedals relay (non-memory) - Electronic back light (EBL) run only relay Electrical inputs: - Headlamp battery supplies 1 & 2 - Module battery supply - Power ground - Ignition switch RUN or START position status - Ignition switch START only status - PCI Bus - Stop lamp switch - Horn switch - Back-up switch - Wiper park switch - Washer fluid level switch - Brake fluid level switch - Ambient temperature sensor - Right park lamp outage - Left park lamp outage - Battery IOD - Battery (+) connection detection - Flash reprogramming voltage CONTROLLED POWER FEEDS Front airbag system The FCM provides power to the Occupant Restraint Control (ORC) system through two fuseless circuits (ORC RUN/START, and ORC RUN only). These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied while the ignition switch is in the RUN and START positions on pin 48 of the FCM connector, and in the RUN only position on pin 29. Headlamp power The headlamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a headlamp switch status change. The FCM then turns on power to the headlamps through four fuseless circuits. These circuits are electronically controlled and continuously monitored for malfunctions.Power is supplied to each filament in a separate circuit. For vehicles equipped with Daytime Running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination. EATX power The electronic automatic 4 speed transmission module is powered when the ignition switch is in the UNLOCK, RUN or START positions. This circuit is Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 6644 electronically controlled and continuously monitored for malfunctions. Power is supplied through pin 27 of the FCM connector. Front washer motor The front washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The front washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition, the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Rear washer motor The rear washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The rear washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition,the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Cabin Heater When the ignition is in Run, the FCM monitors the PCI bus for the Cabin Heater Activation request. The Automatic or Manual Temperature Control initiates this request only when all conditions for the Cabin Heater activation are favorable. The request carries the status bit that the FCM requires to activate its Cabin Heater Assist Control output. This output is a low side driver (coming from FCM pin 15) which supplies a ground signal to the Cabin Heater (pin 5). When the Cabin Heater receives this ground signal input, it interprets this as an activation signal. The FCM low side driver is also capable of diagnostic sensing. The driver will sense an open circuit when the driver is off, and will sense a short to voltage when the driver is on. The FCM will set DTC's for both of these types of faults. For additional information, refer to Cabin Heater under General Information and Diagnostic Procedures. Brake shift interlock system The brake shift interlock solenoid receives power from both high side and low side controls inside the FCM. The high side control is on the same circuit as the EATX module power, and the low side control comes through pin 47 of the FCM connector. The solenoid is controlled by the low side driver when the brake pedal is pressed. Both circuits are continuously monitored for malfunctions. RELAY CONTROLS Fog lamp relay The fog lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the fog lamp relay. The fog lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Fog lamp functionality is not equipped on all vehicles. The FCM learns that the vehicle is equipped with fog lamps by reading the BCM PCI Bus message. Park lamp relay The park lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the park lamp relay. The park lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper on relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper on relay. The front wiper on relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper high/low relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper high/ low relay. The relay switches power between the low speed and high speed windings of the wiper motor. The front wiper high/low relay is powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Accessory relay The accessory relay works in conjunction with the FCM's power accessory delay feature to control the operation of the radio, power windows, washer motors,wiper motors and power outlet. The accessory relay is turned on through low side control on pin 35 of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Depending on the ignition switch position, the accessory relay will remain on or will time-out and turn off. The accessory relay remains on in the RUN and ACCY positions of the ignition switch. In the UNLK and OFF positions, the relay will remain energized for 45 seconds then turn off. During this time-out period, if the driver or passenger doors are opened, the relay will turn off immediately. While the ignition switch is in the START position, the relay will also drop-out, then resume operation. Accessory relay operation is most Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 6645 noticeable by observing the operation of the radio or blower functions. Horn relay The horn relay operates through a direct wire input to the FCM from the horn switch (FCM pin 17) , or a PCI Bus message from the BCM. The relay responds to the horn switch, remote door lock and VTA alarm functions. The horn relay is powered through low side control on pin 10 of the FCM. Under normal operating conditions, if the horn is pressed for longer than 30 seconds, the FCM will automatically deactivate the horn to prevent damage to it. The FCM will re-activate control of the relay after a 25 second cool-down period. This circuit is electronically controlled and continuously monitored for malfunctions. Front and rear blower relay RS with MTC Upon ignition on, the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus.The front blower relay and the rear blower relay, if equipped, are then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. RG with MTC Upon power up (Power switch on), the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus. The front blower relay is then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. Name Brand Speakers (NBS) relay The NBS relay operates through the vehicle bus interface between the radio and the FCM. When the radio is turned on, the radio sends a PCI Bus message to the FCM. The NBS relay is then powered on through low side control on pin 11 of the FCM. The relay supplies power to the amplified speaker, and ground is supplied through the radio. This circuit is electronically controlled and continuously monitored for malfunctions. Electronic Back Light (EBL) relay The rear defrost switch is part of the Automatic Temperature Control or A/C-Heater Control Module (Manual Temp). When the ignition switch is in the RUN position and the rear defrost switch is turned on, the ATC or A/C-Heater Control Module sends a PCI Bus message to the FCM. The EBL run only relay is then powered through low side control on pin 31 of the FCM. The relay provides the high side to the rear window defrost grid, and ground is attached to the vehicle body. The FCM will only allow the rear defrost to operate in the RUN position. This circuit is electronically controlled and continuously monitored for malfunctions. Adjustable Pedals Relay (Non-Memory) The Adjustable Pedals Relay is only on nonmemory Adjustable Pedals System equipped vehicles. The relay is supplied battery voltage from the IPM and is electronically controlled with a low side driver within the FCM. The relay is energized when the transmission is in reverse and when cruise control operation is engaged. This action disables the Adjustable Pedals System from movement. This circuit is continuously monitored for proper function. ELECTRICAL INPUTS Headlamp battery supplies 1 & 2 - 12 volt input on pins 1 and 2. Battery supply voltage for switching headlamp circuits only. Module battery supply - 12 volt input on pin 9. Battery supply voltage for all other FCM operations. Power ground - Ground source on pin 8 for all FCM operations. Ignition switch RUN or START position status - 12 volt input on pin 37. Allows the FCM to determine the ignition switch status for related FCM operations. PCI Bus - Approximately 7.5 volt input on pin 22. Allows the FCM to communicate with other modules on the vehicle bus. Stop lamp Switch status - 12 volt input on pin 44. Provides for brake shift interlock function. Horn Switch - Ground input on pin 17. Primary means for engaging the horn. Back-up switch - Ground input on pin 39. Input is converted to a PCI Bus status message for use by other modules. Wiper park switch - Ground input on pin 16. Used to determine park placement of wipers. Also used as feedback to FCM to determine correct operating mode of wipers. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 6646 Washer fluid level switch - Ground input to pull-up on pin 18. Ground is switched into the circuit when washer bottle fluid level is low. Brake fluid level switch - Ground input to pull-up on pin 36. Ground is switched into the circuit when brake fluid level is low. Ambient temperature sensor - Resistive input to pull-up on pin 25. Corresponding voltage level is converted to a PCI Bus message for use by other modules on the bus. Right park lamp outage - 12 volt input on pin 21. Used to determine if right park lamp circuit is operating properly. Left park lamp outage - 12 volt input on pin 41. Used to determine if left park lamp circuit is operating properly. Battery IOD - 12 volt input on pin 20. The FCM enters a low power consumption mode when the ignition is turned OFF. This low current draw battery supply keeps the microprocessor functioning in the low power mode. Battery (+) connection detection - 12 volt input on pin 38. The battery connection on the PDC incorporates the use of an internal switch to determine if the connector is properly mated and the Connector Positive Assurance (CPA) is engaged. If the CPA is not properly engaged, a voltage on pin 38 will be interpreted as an unseated connector and a fault will set. Flash programming voltage - 20 volt input on pin 42. When a DRBIII(R) is connected and the proper flash reprogramming sequence is selected, the 20 volt signal will be applied through pin 42. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 6647 Power Distribution Module: Testing and Inspection The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any front control module related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool, such as the DRB III(R). The most reliable, efficient, and accurate means to diagnose the front control module requires the use of a DRB III(R) scan tool and the proper Body Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. For information regarding Trouble Code Diagnostic Charts for this system, please refer to Body Control Module testing. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect the negative and positive battery cables. 2. Remove the battery thermal guard. 3. Remove the battery. Integrated Power Module 4. Using a flat-bladed screwdriver, twist the Integrated Power Module (IPM) bracket retaining latch outward to free the IPM from its mounting bracket Disconnecting IPM 5. Rotate the IPM counter-clockwise to access and disconnect the electrical connectors. 6. Remove the IPM bracket clips from the hinge. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 6650 1. Snap the left side of the Integrated Power Module (IPM) housing in its mounting bracket and connect the various electrical connectors. NOTE: Ensure that the Connector Positive Assurance (CPA) on the five-pin B+ connector is positively engaged to prevent generating a Diagnostic Trouble Code (DTC). 2. Rotate the IPM clock-wise until secured in mounting bracket. An audible click may be heard. 3. Install the battery. 4. Install the battery thermal guard. 5. Connect the negative and positive battery cables. 6. Using a scan tool, check for any stored diagnostic trouble codes. Ensure that all vehicle options are operational. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 6651 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the negative and positive battery cables from the battery. 2. Remove the battery. Removing Integrated Power Module 3. Using a long flat-bladed screwdriver, gently twist the Integrated Power Module (IPM) retaining clip outboard to free the IPM from its mounting bracket. Rotate IPM upward to access the Front Control Module (FCM) retaining screws. 4. Remove the front control module retaining screws. Front Control Module 5. Pull the FCM straight from the IPM assembly to disconnect the electrical connector and remove the FCM from the vehicle. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 6652 NOTE: Front Control Module must be programmed to the correct radio EQ curve using the DRB III(R). This will ensure that the audio system is operating correctly. 1. Install the Front Control Module (FCM) in the Integrated Power Module (IPM) assembly by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 1 N.m (7 in. lbs). 3. Rotate the IPM assembly downward to secure in mounting bracket. 4. Install the battery in the vehicle. 5. Connect the positive and negative battery cables. 6. Using the DRB III(R), under "FRONT CONTROL MODULE" then "MISC" program the EQ curve of the radio into the Front Control Module. NOTE: If the vehicle is not equipped with Name Brand Speakers (Infinity, etc.) or Headlamp Washers the DRB IIIT must be used to Disable the appropriate relays in the Integrated Power Module Assembly Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is removed from its normal cavity in the Integrated Power Module (IPM) when the vehicle is shipped from the factory. Dealer personnel are to remove the IOD fuse from the storage location and install it into the IPM fuse cavity marked IOD as part of the preparation procedures performed just prior to new vehicle delivery. The IOD fuse is a 20 ampere blade-type mini fuse and, when removed, it is stored in a fuse cavity adjacent to the washer fuse within the IPM. The term ignition-off draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position, including the clock. The only reason the IOD fuse is removed is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is removed from the Integrated Power Module (IPM) fuse cavity when the vehicle is shipped from the assembly plant. Dealer personnel must install the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed approximately thirty days. However, it must be remembered that removing the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Component Locations > Page 6661 Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Page 6662 Front Control Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module Power Distribution Module: Description and Operation Integrated Power Module Integrated Power Module The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) and the Front Control Module (FCM). The IPM is located in the engine compartment, next to the battery.The PDC mates directly with the FCM to form the IPM. The PDC is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. This IPM connects directly to the battery positive through a four pin connector. The ground connection is through two other connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. All of the current from the battery and the generator output enters the Integrated Power Module (IPM) through a four pin connector on the bottom of the module. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 6665 Power Distribution Module: Description and Operation Front Control Module The Front Control Module (FCM) is an electrical control and interface center located in the engine compartment. When it is mated to the Power Distribution Center (PDC), it is referred to as the Integrated Power Module (IPM). The IPM, with its fuses and relays provides power and signal distribution throughout most of the vehicle. The FCM receives both hard wire and digital electronic inputs from the vehicle electrical system through the PDC. Based on these inputs and the ignition switch position, it provides direct power feeds and relay control to some of the vehicles most critical electrical systems. The Front Control Module provides the following features: Controlled power feeds: - Front airbag system - Headlamp power - EATX module power (4 speed only) - Front washer motor - Rear washer motor - Cabin Heater - Brake shift interlock system Relay controls: - Fog lamp relay (when equipped) - Park lamp relay - Front wiper on relay - Front wiper high/low relay - Accessory relay - Horn relay - Front & rear blower relay - Name brand speakers (NBS) relay - Adjustable pedals relay (non-memory) - Electronic back light (EBL) run only relay Electrical inputs: - Headlamp battery supplies 1 & 2 - Module battery supply - Power ground - Ignition switch RUN or START position status - Ignition switch START only status - PCI Bus - Stop lamp switch - Horn switch - Back-up switch - Wiper park switch - Washer fluid level switch - Brake fluid level switch - Ambient temperature sensor - Right park lamp outage - Left park lamp outage - Battery IOD - Battery (+) connection detection - Flash reprogramming voltage CONTROLLED POWER FEEDS Front airbag system The FCM provides power to the Occupant Restraint Control (ORC) system through two fuseless circuits (ORC RUN/START, and ORC RUN only). These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied while the ignition switch is in the RUN and START positions on pin 48 of the FCM connector, and in the RUN only position on pin 29. Headlamp power The headlamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a headlamp switch status change. The FCM then turns on power to the headlamps through four fuseless circuits. These circuits are electronically controlled and continuously monitored for malfunctions.Power is supplied to each filament in a separate circuit. For vehicles equipped with Daytime Running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination. EATX power The electronic automatic 4 speed transmission module is powered when the ignition switch is in the UNLOCK, RUN or START positions. This circuit is Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 6666 electronically controlled and continuously monitored for malfunctions. Power is supplied through pin 27 of the FCM connector. Front washer motor The front washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The front washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition, the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Rear washer motor The rear washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The rear washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition,the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Cabin Heater When the ignition is in Run, the FCM monitors the PCI bus for the Cabin Heater Activation request. The Automatic or Manual Temperature Control initiates this request only when all conditions for the Cabin Heater activation are favorable. The request carries the status bit that the FCM requires to activate its Cabin Heater Assist Control output. This output is a low side driver (coming from FCM pin 15) which supplies a ground signal to the Cabin Heater (pin 5). When the Cabin Heater receives this ground signal input, it interprets this as an activation signal. The FCM low side driver is also capable of diagnostic sensing. The driver will sense an open circuit when the driver is off, and will sense a short to voltage when the driver is on. The FCM will set DTC's for both of these types of faults. For additional information, refer to Cabin Heater under General Information and Diagnostic Procedures. Brake shift interlock system The brake shift interlock solenoid receives power from both high side and low side controls inside the FCM. The high side control is on the same circuit as the EATX module power, and the low side control comes through pin 47 of the FCM connector. The solenoid is controlled by the low side driver when the brake pedal is pressed. Both circuits are continuously monitored for malfunctions. RELAY CONTROLS Fog lamp relay The fog lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the fog lamp relay. The fog lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Fog lamp functionality is not equipped on all vehicles. The FCM learns that the vehicle is equipped with fog lamps by reading the BCM PCI Bus message. Park lamp relay The park lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the park lamp relay. The park lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper on relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper on relay. The front wiper on relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper high/low relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper high/ low relay. The relay switches power between the low speed and high speed windings of the wiper motor. The front wiper high/low relay is powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Accessory relay The accessory relay works in conjunction with the FCM's power accessory delay feature to control the operation of the radio, power windows, washer motors,wiper motors and power outlet. The accessory relay is turned on through low side control on pin 35 of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Depending on the ignition switch position, the accessory relay will remain on or will time-out and turn off. The accessory relay remains on in the RUN and ACCY positions of the ignition switch. In the UNLK and OFF positions, the relay will remain energized for 45 seconds then turn off. During this time-out period, if the driver or passenger doors are opened, the relay will turn off immediately. While the ignition switch is in the START position, the relay will also drop-out, then resume operation. Accessory relay operation is most Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 6667 noticeable by observing the operation of the radio or blower functions. Horn relay The horn relay operates through a direct wire input to the FCM from the horn switch (FCM pin 17) , or a PCI Bus message from the BCM. The relay responds to the horn switch, remote door lock and VTA alarm functions. The horn relay is powered through low side control on pin 10 of the FCM. Under normal operating conditions, if the horn is pressed for longer than 30 seconds, the FCM will automatically deactivate the horn to prevent damage to it. The FCM will re-activate control of the relay after a 25 second cool-down period. This circuit is electronically controlled and continuously monitored for malfunctions. Front and rear blower relay RS with MTC Upon ignition on, the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus.The front blower relay and the rear blower relay, if equipped, are then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. RG with MTC Upon power up (Power switch on), the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus. The front blower relay is then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. Name Brand Speakers (NBS) relay The NBS relay operates through the vehicle bus interface between the radio and the FCM. When the radio is turned on, the radio sends a PCI Bus message to the FCM. The NBS relay is then powered on through low side control on pin 11 of the FCM. The relay supplies power to the amplified speaker, and ground is supplied through the radio. This circuit is electronically controlled and continuously monitored for malfunctions. Electronic Back Light (EBL) relay The rear defrost switch is part of the Automatic Temperature Control or A/C-Heater Control Module (Manual Temp). When the ignition switch is in the RUN position and the rear defrost switch is turned on, the ATC or A/C-Heater Control Module sends a PCI Bus message to the FCM. The EBL run only relay is then powered through low side control on pin 31 of the FCM. The relay provides the high side to the rear window defrost grid, and ground is attached to the vehicle body. The FCM will only allow the rear defrost to operate in the RUN position. This circuit is electronically controlled and continuously monitored for malfunctions. Adjustable Pedals Relay (Non-Memory) The Adjustable Pedals Relay is only on nonmemory Adjustable Pedals System equipped vehicles. The relay is supplied battery voltage from the IPM and is electronically controlled with a low side driver within the FCM. The relay is energized when the transmission is in reverse and when cruise control operation is engaged. This action disables the Adjustable Pedals System from movement. This circuit is continuously monitored for proper function. ELECTRICAL INPUTS Headlamp battery supplies 1 & 2 - 12 volt input on pins 1 and 2. Battery supply voltage for switching headlamp circuits only. Module battery supply - 12 volt input on pin 9. Battery supply voltage for all other FCM operations. Power ground - Ground source on pin 8 for all FCM operations. Ignition switch RUN or START position status - 12 volt input on pin 37. Allows the FCM to determine the ignition switch status for related FCM operations. PCI Bus - Approximately 7.5 volt input on pin 22. Allows the FCM to communicate with other modules on the vehicle bus. Stop lamp Switch status - 12 volt input on pin 44. Provides for brake shift interlock function. Horn Switch - Ground input on pin 17. Primary means for engaging the horn. Back-up switch - Ground input on pin 39. Input is converted to a PCI Bus status message for use by other modules. Wiper park switch - Ground input on pin 16. Used to determine park placement of wipers. Also used as feedback to FCM to determine correct operating mode of wipers. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module > Page 6668 Washer fluid level switch - Ground input to pull-up on pin 18. Ground is switched into the circuit when washer bottle fluid level is low. Brake fluid level switch - Ground input to pull-up on pin 36. Ground is switched into the circuit when brake fluid level is low. Ambient temperature sensor - Resistive input to pull-up on pin 25. Corresponding voltage level is converted to a PCI Bus message for use by other modules on the bus. Right park lamp outage - 12 volt input on pin 21. Used to determine if right park lamp circuit is operating properly. Left park lamp outage - 12 volt input on pin 41. Used to determine if left park lamp circuit is operating properly. Battery IOD - 12 volt input on pin 20. The FCM enters a low power consumption mode when the ignition is turned OFF. This low current draw battery supply keeps the microprocessor functioning in the low power mode. Battery (+) connection detection - 12 volt input on pin 38. The battery connection on the PDC incorporates the use of an internal switch to determine if the connector is properly mated and the Connector Positive Assurance (CPA) is engaged. If the CPA is not properly engaged, a voltage on pin 38 will be interpreted as an unseated connector and a fault will set. Flash programming voltage - 20 volt input on pin 42. When a DRBIII(R) is connected and the proper flash reprogramming sequence is selected, the 20 volt signal will be applied through pin 42. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Page 6669 Power Distribution Module: Testing and Inspection The Front Control Module (FCM) is a printed circuit board based module with a on-board micro-processor. The FCM interfaces with other electronic modules in the vehicle via the Programmable Communications Interface (PCI) data bus. In order to obtain conclusive testing the PCI data bus and all of the electronic modules that provide inputs to, or receive outputs from the FCM must be checked. All PCI communication faults must be resolved prior to further diagnosing any front control module related issues. The FCM was designed to be diagnosed with an appropriate diagnostic scan tool, such as the DRB III(R). The most reliable, efficient, and accurate means to diagnose the front control module requires the use of a DRB III(R) scan tool and the proper Body Diagnostic Procedures. Before any testing of the FCM is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle. For information regarding Trouble Code Diagnostic Charts for this system, please refer to Body Control Module testing. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module Power Distribution Module: Service and Repair Integrated Power Module REMOVAL 1. Disconnect the negative and positive battery cables. 2. Remove the battery thermal guard. 3. Remove the battery. Integrated Power Module 4. Using a flat-bladed screwdriver, twist the Integrated Power Module (IPM) bracket retaining latch outward to free the IPM from its mounting bracket Disconnecting IPM 5. Rotate the IPM counter-clockwise to access and disconnect the electrical connectors. 6. Remove the IPM bracket clips from the hinge. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 6672 1. Snap the left side of the Integrated Power Module (IPM) housing in its mounting bracket and connect the various electrical connectors. NOTE: Ensure that the Connector Positive Assurance (CPA) on the five-pin B+ connector is positively engaged to prevent generating a Diagnostic Trouble Code (DTC). 2. Rotate the IPM clock-wise until secured in mounting bracket. An audible click may be heard. 3. Install the battery. 4. Install the battery thermal guard. 5. Connect the negative and positive battery cables. 6. Using a scan tool, check for any stored diagnostic trouble codes. Ensure that all vehicle options are operational. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 6673 Power Distribution Module: Service and Repair Front Control Module REMOVAL 1. Disconnect and isolate the negative and positive battery cables from the battery. 2. Remove the battery. Removing Integrated Power Module 3. Using a long flat-bladed screwdriver, gently twist the Integrated Power Module (IPM) retaining clip outboard to free the IPM from its mounting bracket. Rotate IPM upward to access the Front Control Module (FCM) retaining screws. 4. Remove the front control module retaining screws. Front Control Module 5. Pull the FCM straight from the IPM assembly to disconnect the electrical connector and remove the FCM from the vehicle. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module > Page 6674 NOTE: Front Control Module must be programmed to the correct radio EQ curve using the DRB III(R). This will ensure that the audio system is operating correctly. 1. Install the Front Control Module (FCM) in the Integrated Power Module (IPM) assembly by pushing the 49-way electrical connector straight in. 2. Install the FCM retaining screws. Torque the screws to 1 N.m (7 in. lbs). 3. Rotate the IPM assembly downward to secure in mounting bracket. 4. Install the battery in the vehicle. 5. Connect the positive and negative battery cables. 6. Using the DRB III(R), under "FRONT CONTROL MODULE" then "MISC" program the EQ curve of the radio into the Front Control Module. NOTE: If the vehicle is not equipped with Name Brand Speakers (Infinity, etc.) or Headlamp Washers the DRB IIIT must be used to Disable the appropriate relays in the Integrated Power Module Assembly Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6679 Relay Box: Locations Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6680 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6681 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6682 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6683 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6684 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6685 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6686 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6687 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6688 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6689 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6692 Relay Box: Application and ID Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6693 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6694 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6695 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6696 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6697 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6698 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6699 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6700 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6701 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6706 Relay Box: Locations Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6707 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6708 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6709 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6710 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6711 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6712 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6713 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6714 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Fuses Integrated Power Module > Page 6715 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Page 6716 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6719 Relay Box: Application and ID Integrated Power Module m 8w-13-03 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6720 Integrated Power Module Front View 8w-13-05 Integrated Power Module Rear View Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6721 8w-13-06 Fuses Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6722 8w-13-07 Positive Temp Coefficient Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6723 8w-13-08 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6724 8w-13-09 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6725 8w-13-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6726 8w-13-11 Relays Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6727 8w-13-12 Front Control Module Connector Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Fuses Integrated Power Module > Page 6728 8w-13-05 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Power Interrupt Connector/Switch > Component Information > Description and Operation Power Interrupt Connector/Switch: Description and Operation All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is removed from its normal cavity in the Integrated Power Module (IPM) when the vehicle is shipped from the factory. Dealer personnel are to remove the IOD fuse from the storage location and install it into the IPM fuse cavity marked IOD as part of the preparation procedures performed just prior to new vehicle delivery. The IOD fuse is a 20 ampere blade-type mini fuse and, when removed, it is stored in a fuse cavity adjacent to the washer fuse within the IPM. The term ignition-off draw (IOD) identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position, including the clock. The only reason the IOD fuse is removed is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehicle transportation company and dealer personnel. The IOD fuse is removed from the Integrated Power Module (IPM) fuse cavity when the vehicle is shipped from the assembly plant. Dealer personnel must install the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse. The IOD fuse serves no useful purpose to the dealer technician in the service or diagnosis of any vehicle system or condition, other than the same purpose as that of any other standard circuit protection device. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed approximately thirty days. However, it must be remembered that removing the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The use of tire sealants is strictly prohibited for vehicles equipped with the Tire Pressure Monitoring system. Tire sealants can clog tire pressure sensors. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. CAUTION: Any time a sensor is to be installed in a wheel, a new seal and washer must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 6742 Tire Pressure Sensor: Description and Operation SENSOR - TPM DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor is mounted to each wheel in place of the traditional tire valve stem (Fig. 18). Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency (Fig. 18). The TPM sensors are designed for original style factory wheels. Do not attempt to install a tire pressure sensor in an aftermarket wheel. The serviceable components of the tire pressure sensor are (Fig. 19): Sensor-To-Wheel Seal and Metal Washer - Valve Stem Cap - Valve Stem Core - Valve Stem Nut Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 6743 The valve stem caps and cores used are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. OPERATION The battery operated tire pressure sensors lay dormant (Park Mode), then wake and start transmitting (Drive Mode) when the vehicle first reaches speeds over 15 mph (24 km/h). Once the wheels stop rotating for a period of approximately 20 minutes, the sensors shut down until again awaken. Although not transmitting as when in Drive Mode, while in Park Mode, the sensors still transmit approximately once every 13 hours to let the receiver know air pressure status at that time. Using an RF signal, each sensor transmits tire pressure data approximately once every minute. Each sensor's (transmitter) broadcast is uniquely coded so that the Sentry Key Remote Entry Module (SKREEM) can monitor the state of each of the sensors on the four rotating road wheels. The SKREEM automatically learns and stores the sensor's ID while driving after a sensor has been replaced. There is no formal retraining procedure necessary. For additional information, refer to appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 6744 Tire Pressure Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TIRE PRESSURE SENSOR NOTE: Tire pressure may increase from 2 to 6 psi (14 to 41 kPa) during normal driving conditions. Do NOT reduce this normal pressure build up. When diagnosing a tire pressure issue, always check air pressure in the tires first with a known accurate air gauge. Adjust air pressure as necessary to that listed on the Tire Inflation Pressure Label (Placard) provided with the vehicle (usually applied to the driver's side B-pillar). After adjusting air pressure in a tire, allow approximately two minutes for the message or indicator lamp to go out. Check the tire pressure indicator lamp in the instrument cluster. If the lamp is illuminating continuously, proceed as listed. If the indicator lamp is flashing on/off three times, once every ten minutes, there is a system fault detected. Refer to the appropriate diagnostic information. If air pressure in any tire is low, inspect all the tires for leaks. A water "dunk tank" or other water test may be used to check for a leak around the sensor as long as any water at the valve core is removed once the procedure is completed. The water can be easily expelled from the core area by pushing in on the core for several seconds, allowing escaping air to drive out any moisture. Reinflate the tire as necessary. Always make sure the original valve stem cap is securely installed to keep moisture out of the sensor. If the gauge-read pressure in the tires does not indicate a tire pressure issue, refer to the appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 6745 Tire Pressure Sensor: Service and Repair TIRE PRESSURE SENSOR REMOVAL 1. Remove tire and wheel assembly from vehicle. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 2. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor. That includes both front and rear beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool at the valve stem ± 10° (Fig. 20), then proceed to dismount the tire from the wheel. Use this process on both the upper and lower tire beads. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 6746 3. Remove sensor nut retaining sensor to wheel (Fig. 21). While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 4. Remove sensor from wheel (Fig. 21). INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal and metal washer at base of valve stem to ensure proper sealing (Fig. 22). 1. Wipe area clean around sensor/valve stem mounting hole in wheel. Make sure surface of wheel is not damaged. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 6747 CAUTION: To avoid damaging sensor antenna strap (Fig. 23), hold pressure against rear of metal valve stem (Fig. 24) while sensor is inserted through wheel mounting hole and nut is installed. 2. Insert sensor through wheel as shown keeping pressure against rear of metal valve stem. (Fig. 24). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) by hand (Fig. 24). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 6748 NOTE: Before tightening sensor nut, push downward on sensor housing in an attempt to make it flush with interior contour of wheel (Fig. 25). 4. While holding sensor in position, tighten sensor nut to 6.5 Nm (58 inch lbs.) torque. CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 inch lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function, however, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem approximately 210° from the head of the changer in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire (Fig. 26). Use this procedure on both the upper and lower tire beads. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 6749 b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem is approximately 210° from the head of the changer in a clockwise direction from the mounting end of the tool (Fig. 27) Make sure the sensor is clear of the lower bead breaker area to avoid damaging the sensor when the breaker rises (Fig. 27). Rotate the tool in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install wheel and tire assembly on vehicle. 8. Drive vehicle for a minimum of five minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time the system will learn the new sensor ID code and will clear any DTCs automatically. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 6756 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 6757 Power Steering Fluid: Technical Service Bulletins Power Steering - Additive Prohibition NUMBER: 19-010-04 GROUP: Steering DATE: November 29, 2004 SUBJECT: Power Steering Fluid Contamination MODELS: 2004 - 2005 (CS) Pacifica 2004 - 2005 (DR/DH) Ram Truck 2004 - 2005 (HB) Durango 2004 - 2005 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2004 - 2005 (KJ) Liberty 2004 - 2005 (LX) 300/Magnum 2004 - 2005 (PL) Neon/SRT4 2004 - 2005 (PT) PT Cruiser 2004 - 2005 (RG) Chrysler Voyager 2004 - 2005 (RS) Town & Country/Caravan/Voyager 2004 - 2005 (ST) Sebring Coupe/Stratus Coupe 2004 - 2005 (TJ) Wrangler 2004 - 2005 (ZB) Viper DISCUSSION: Do not use fluids or supplements that contain Teflon as they will cause a restriction at the filter in the power steering fluid reservoir, causing severe damage to the steering system. The power steering fluid used in Chrysler Group vehicles is an engineered product, the addition of ANY unapproved fluids or supplements can interfere with the proper function of the fluid and cause damage to the steering system. To ensure the performance and durability of Chrysler Group steering systems, use only Mopar Power Steering Fluid +4, ATF+4 Automatic Transmission Fluid, or equivalent (MS-9602), in the power steering system. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 6758 Power Steering Fluid: Specifications Use only Mopar MS9602, ATF+4 Type 9602. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 6759 Power Steering Fluid: Testing and Inspection STANDARD PROCEDURE - POWER STEERING FLUID LEVEL CHECKING WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT INJURY FROM MOVING PARTS AND TO ENSURE ACCURATE FLUID LEVEL READING. The fluid level can be read on the exterior of the power steering fluid reservoir. The fluid level should be within the "FILL RANGE" when the fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F) (Fig. 17). Before removing the power steering filler cap, wipe the reservoir filler cap free of dirt and debris. Do not overfill the power steering system. Use only Mopar ATF+4 Automatic Transmission Fluid (MS-9602) in the power steering system. CAUTION: Use only Mopar ATF+4 Automatic Transmission Fluid (MS-9602). Use of other Mopar power steering fluids (MS5931 and MS9933) should be avoided to ensure peak performance of the power steering system under all operating conditions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder Power Steering Fluid Cooler: Customer Interest Steering - Low Speed Steering Shudder NUMBER: 19-006-05 GROUP: Steering DATE: August 4, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-004-03, DATED AUGUST 29, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Steering Shudder OVERVIEW: This bulletin involves replacing one of the two power steering cooler hoses with a new longer power steering hose and if necessary, installing a fin packed power steering cooler. MODELS: 2001 - 2005 (RS) Town & Country, Caravan, Voyager 2001 - 2005 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to right hand and left hand drive vehicles equipped with a 3.3L or 3.8L engine (sales code EGA, EGM, EGH) built on or before December 8, 2004 (MDH 1208XX) SYMPTOM/CONDITION: A shudder (vibration) is felt inside the vehicle while turning the steering wheel at idle or during low speeds such as a parking lot maneuver. The shudder may be felt in the steering wheel, seat, and/or body. DIAGNOSIS: 1. Verify the condition: - Perform stationary turns and/or low speed turns in drive and reverse. Perform the evaluation with the A/C in the on and off position. Is steering shudder detected? a. Yes » Go to Step # 2. b. No» Further diagnosis is needed, this bulletin does not apply. 2. Inspect for the presence of a power steering finned cooler. Is a finned cooler present? a. Yes » Go to "Replace Power Steering Hose - Step # 1". b. No. » Go to "Install Finned Cooler - Step # 1". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6768 PARTS REQUIRED INSTALL FINNED COOLER: CAUTION: Throughout the following procedure, special care should be taken to prevent introducing contamination into the power steering system. 1. Open the hood. 2. Remove the cap from the power steering fluid reservoir. 3. Using a siphon pump/suction gun, remove as much power steering fluid as possible from the power steering fluid reservoir. 4. Remove and save the constant tension spring clamp securing the power steering return line hose to the power steering fluid reservoir. 5. Remove the rubber hose portion of the power steering return line from the power steering fluid reservoir fitting. 6. Drain the power steering fluid reservoir into an appropriate container. NOTE: This fluid should not be reused to avoid introducing contamination from the container. 7. Raise the vehicle on an appropriate hoist. 8. Remove the fuel vapor canister. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6769 9. Locate the bracket connecting the power steering return line cooler loop to the cradle reinforcement plate (Fig. 1). 10. Remove the fasteners connecting the cooler line to the reinforcement plate. Save the fasteners for use in Step # 17. 11. Locate the bracket connecting the power steering pressure line to the cradle reinforcement plate (Fig. 1). 12. Remove the fastener connecting the bracket to the reinforcement plate. Save the fastener for use in Step # 18. 13. Remove and discard the J/U nut clip on the bracket. 14. Locate and unscrew the tube nut connecting the power steering return line to the steering gear pinion housing. NOTE: The tube nut will remain loosely assembled to the power steering return line. 15. Drain the remaining fluid into an appropriate container and discard the loop cooler line that was removed from the vehicle. NOTE: This fluid should not be reused to avoid introducing contamination from the container. 16. Install the new power steering return line, p/n 04743473AE. Attach the power steering return line tube nut to the steering gear pinion housing and tighten to 27.1 - 35.0 Nm (240 - 310 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6770 17. Reuse the fastener removed in Step # 10. Install the fastener into the left weld nut on the cooler fin pack bracket and the left hole in the cradle reinforcement plate. Tighten the fastener to 9 - 11.3 Nm (80-100 in. lbs.) (Fig. 2). 18. Line up the pressure line bracket and the right weld nut in the cooler fin pack bracket. Reuse the fastener removed in Step # 12. Install the fastener through the right hole in the cradle reinforcement plate, the fin pack bracket and the pressure line bracket. Tighten the fastener to 9 11.3 Nm (80-100 in. lbs.) (Fig. 2). 19. Install the fuel vapor canister. 20. Lower the vehicle. 21. Install the constant tension spring clamp removed in Step # 4 onto the rubber hose on the power steering return line. Slide the clamp so that it is 3 inches from the end of the rubber hose. 22. Push the end of the rubber hose portion of the power steering return line onto the power steering fluid reservoir suction port. Secure the hose by sliding the constant spring tension clamp installed on the hose in the last step, to within 6 mm (0.25 in.) of the end of the rubber hose. Be sure the hose clamp is installed past the bead on fluid reservoir fitting. 23. Check the vehicle production date. Was the vehicle built on or before September 13, 2004 (MDH 091344XX)? a. Yes » Go to "Replace Power Steering Hose - Step # 1". b. No » Go to "Steering/pump - Standard Procedure - Step # 1". REPLACE POWER STEERING HOSE: 1. Cut 850 mm (33.5 in.) of power steering hose (p/n 05135964AA) or equivalent. 2. Cut 790 mm (31 in.) of 15.9 mm (5/8 in.) or 17.5 mm (11/16 in.) convolute tubing. Place the convolute tubing around the power steering hose. 3. Open hood and remove the power steering reservoir cap. 4. Raise the vehicle on an appropriate hoist. 5. Locate the power steering cooler attached to the crossmember support. Remove the forward (closest to front of vehicle) hose from the cooler and tube. Drain the power steering fluid in an appropriate container. 6. Remove the two tension clamps from the removed hose and install on the new power steering return hose. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6771 7. Install the new hose and tension clamp onto the power steering cooler. 8. Wrap the hose clockwise around the perimeter and on top of the power steering cooler as shown in (Fig. 3). Install the hose and tension clamp to the power steering return tube. 9. Use two tie straps to strap the return hose to the power steering cooler and pressure steering hose shown in (Fig. 3). 10. Lower vehicle and open hood. 11. Proceed to "Steering/Pump - Standard Procedure". STEERING/PUMP - STANDARD PROCEDURE WARNING: FLUID LEVEL SHOULD BE CHECKED AND ADJUSTED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING ENGINE COMPONENTS. CAUTION: Use only Mopar(R) ATF+4 Automatic Transmission Fluid (MS-9602) in power steering system. Use of other Mopar(R) power steering fluids (MS5931 and MS9933) should be avoided to ensure peak performance of the power steering system under all operating conditions. Do not overfill. Read the fluid level through the side of the power steering fluid reservoir. The fluid level should be within "FILL RANGE" when the fluid is at a temperature of approximately 21°C to 27°C (70°F to 80°F). 1. Wipe the filler cap and area clean, then remove the cap. 2. Fill the fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 3. Start the engine and let run for a few seconds, then turn the engine off. 4. Add fluid if necessary. Repeat the above steps until the fluid level remains constant after running the engine. 5. Raise the front wheels off the ground. 6. Start the engine. 7. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6772 8. Add fluid if necessary. 9. Lower the vehicle, then turn the steering wheel slowly from lock-to-lock. 10. Stop the engine. Check the fluid level and refill as required. 11. If the fluid is extremely foamy, allow the vehicle to stabilize a few minutes, then repeat the above procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE: P8 New Part 68 Noisy Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 19-011-04 > Dec > 04 > Steering - Moaning Noise on Low Speed Turns Power Steering Fluid Cooler: Customer Interest Steering - Moaning Noise on Low Speed Turns NUMBER: 19-011-04 GROUP: Steering DATE: December 7, 2004 SUBJECT: Moan/Fog Horn Like Sound While Turning During Slow Speed Or Parking Lot Maneuvers. OVERVIEW: This bulletin involves installing a finned power steering fluid cooler package and if necessary, a steering gear. MODELS: 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles built on or before September 13, 2004 (MDH 0913XX). SYMPTOM/CONDITION: The vehicle operator may describe a moan/fog horn like sound while turning during slow speed or parking lot maneuvers. The sound may occur throughout the steering range, off center, but not at the wheel stops. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: CAUTION: Throughout the following procedure, special care should be taken to prevent introducing contamination into the power steering system. 1. Open the hood. 2. Remove the cap from the power steering fluid reservoir. 3. Using a siphon pump/suction gun, remove as much power steering fluid as possible from the power steering fluid reservoir. 4. Remove and save the constant tension spring clamp securing the power steering return line hose to the power steering fluid reservoir. 5. Remove the rubber hose portion of the power steering return line from the power steering fluid reservoir fitting. 6. Drain the power steering fluid reservoir into an appropriate container. NOTE: This fluid should not be reused to avoid introducing contamination from the container. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 19-011-04 > Dec > 04 > Steering - Moaning Noise on Low Speed Turns > Page 6777 7. Raise the vehicle on an appropriate hoist. 8. Remove the fuel vapor canister. 9. Locate the bracket connecting the power steering return line cooler loop to the cradle reinforcement plate (Fig. 1). 10. Remove the fasteners connecting the cooler line to the reinforcement plate. Save the fasteners for use in Step # 17. 11. Locate the bracket connecting the power steering pressure line to the cradle reinforcement plate (Fig. 1). 12. Remove the fastener connecting the bracket to the reinforcement plate. Save the fastener for use in Step # 18. 13. Remove and discard the J/U nut clip on the bracket. 14. Locate and unscrew the tube nut connecting the power steering return line to the steering gear pinion housing. NOTE: The tube nut will remain loosely assembled to the power steering return line. 15. Drain the remaining fluid into an appropriate container and discard the loop cooler line that was removed from the vehicle. NOTE: This fluid should not be reused to avoid introducing contamination from the container. 16. Install the new power steering return line, p/n 04743473AE. Attach the power steering return line tube nut to the steering gear pinion housing and tighten to 27.1 - 35.0 N.m (240 - 310 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 19-011-04 > Dec > 04 > Steering - Moaning Noise on Low Speed Turns > Page 6778 17. Reuse the fastener removed in Step # 10. Install the fastener into the left weld nut on the cooler fin pack bracket and the left hole in the cradle reinforcement plate. Tighten the fastener to 9-11.3 Nm (80-100 in. lbs.) (Fig. 2). 18. Line up the pressure line bracket and the right weld nut in the cooler fin pack bracket. Reuse the fastener removed in Step # 12. Install the fastener through the right hole in the cradle reinforcement plate, the fin pack bracket and the pressure line bracket. Tighten the fastener to 9 11.3 N.m (80-100 in. lbs.) (Fig. 2). 19. Install the fuel vapor canister. 20. Lower the vehicle. 21. Install the constant tension spring clamp removed in Step # 4 onto the rubber hose on the power steering return line. Slide the clamp so that it is 3 inches from the end of the rubber hose. 22. Push the end of the rubber hose portion of the power steering return line onto the power steering fluid reservoir suction port. Secure the hose by sliding the constant spring tension clamp installed on the hose in the last step, to within 6 mm (0.25 in.) of the end of the rubber hose. Be sure the hose clamp is installed past the bead on fluid reservoir fitting. 23. Fill the power steering system. Refer to Steering/Pump - Standard Procedure at the end of this bulletin. 24. Test drive the vehicle in the parking lot. Determine if the sound, as describe in the Symptom/Condition section of this bulletin, is still present. 25. If the sound is no longer present. The repair is complete. If the sound is still present, replace the steering gear using the appropriate part number according to the Parts Required table above. Refer to the service information available in TechCONNECT. Refer to 19 - Steering/Gear Removal and Installation. 26. Fill the power steering system. Refer to Steering/Pump - Standard Procedure below. STEERING/PUMP - STANDARD PROCEDURE WARNING: FLUID LEVEL SHOULD BE CHECKED AND ADJUSTED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING ENGINE COMPONENTS. CAUTION: Use only Mopar(R) ATF+4 Automatic Transmission Fluid (MS-9602) in power steering system. Use of other Mopar(R) power steering fluids (M55931 and M59933) should be avoided to ensure peak performance of the power steering system under all operating conditions. Do not overfill. Read the fluid level through the side of the power steering fluid reservoir. The fluid level should be within "FILL RANGE" when the fluid is at a temperature of approximately 21 °C to 27°C (70°F to 80°F). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Fluid Cooler: > 19-011-04 > Dec > 04 > Steering - Moaning Noise on Low Speed Turns > Page 6779 1. Wipe the filler cap and area clean, then remove the cap. 2. Fill the fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 3. Start the engine and let run for a few seconds, then turn the engine off. 4. Add fluid if necessary. Repeat the above steps until the fluid level remains constant after running the engine. 5. Raise the front wheels off the ground. 6. Start the engine. 7. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 8. Add fluid if necessary. 9. Lower the vehicle, then turn the steering wheel slowly from lock-to-lock. 10. Stop the engine. Check the fluid level and refill as required. 11. If the fluid is extremely foamy, allow the vehicle to stabilize a few minutes, then repeat the above procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder Power Steering Fluid Cooler: All Technical Service Bulletins Steering - Low Speed Steering Shudder NUMBER: 19-006-05 GROUP: Steering DATE: August 4, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-004-03, DATED AUGUST 29, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Steering Shudder OVERVIEW: This bulletin involves replacing one of the two power steering cooler hoses with a new longer power steering hose and if necessary, installing a fin packed power steering cooler. MODELS: 2001 - 2005 (RS) Town & Country, Caravan, Voyager 2001 - 2005 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to right hand and left hand drive vehicles equipped with a 3.3L or 3.8L engine (sales code EGA, EGM, EGH) built on or before December 8, 2004 (MDH 1208XX) SYMPTOM/CONDITION: A shudder (vibration) is felt inside the vehicle while turning the steering wheel at idle or during low speeds such as a parking lot maneuver. The shudder may be felt in the steering wheel, seat, and/or body. DIAGNOSIS: 1. Verify the condition: - Perform stationary turns and/or low speed turns in drive and reverse. Perform the evaluation with the A/C in the on and off position. Is steering shudder detected? a. Yes » Go to Step # 2. b. No» Further diagnosis is needed, this bulletin does not apply. 2. Inspect for the presence of a power steering finned cooler. Is a finned cooler present? a. Yes » Go to "Replace Power Steering Hose - Step # 1". b. No. » Go to "Install Finned Cooler - Step # 1". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6785 PARTS REQUIRED INSTALL FINNED COOLER: CAUTION: Throughout the following procedure, special care should be taken to prevent introducing contamination into the power steering system. 1. Open the hood. 2. Remove the cap from the power steering fluid reservoir. 3. Using a siphon pump/suction gun, remove as much power steering fluid as possible from the power steering fluid reservoir. 4. Remove and save the constant tension spring clamp securing the power steering return line hose to the power steering fluid reservoir. 5. Remove the rubber hose portion of the power steering return line from the power steering fluid reservoir fitting. 6. Drain the power steering fluid reservoir into an appropriate container. NOTE: This fluid should not be reused to avoid introducing contamination from the container. 7. Raise the vehicle on an appropriate hoist. 8. Remove the fuel vapor canister. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6786 9. Locate the bracket connecting the power steering return line cooler loop to the cradle reinforcement plate (Fig. 1). 10. Remove the fasteners connecting the cooler line to the reinforcement plate. Save the fasteners for use in Step # 17. 11. Locate the bracket connecting the power steering pressure line to the cradle reinforcement plate (Fig. 1). 12. Remove the fastener connecting the bracket to the reinforcement plate. Save the fastener for use in Step # 18. 13. Remove and discard the J/U nut clip on the bracket. 14. Locate and unscrew the tube nut connecting the power steering return line to the steering gear pinion housing. NOTE: The tube nut will remain loosely assembled to the power steering return line. 15. Drain the remaining fluid into an appropriate container and discard the loop cooler line that was removed from the vehicle. NOTE: This fluid should not be reused to avoid introducing contamination from the container. 16. Install the new power steering return line, p/n 04743473AE. Attach the power steering return line tube nut to the steering gear pinion housing and tighten to 27.1 - 35.0 Nm (240 - 310 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6787 17. Reuse the fastener removed in Step # 10. Install the fastener into the left weld nut on the cooler fin pack bracket and the left hole in the cradle reinforcement plate. Tighten the fastener to 9 - 11.3 Nm (80-100 in. lbs.) (Fig. 2). 18. Line up the pressure line bracket and the right weld nut in the cooler fin pack bracket. Reuse the fastener removed in Step # 12. Install the fastener through the right hole in the cradle reinforcement plate, the fin pack bracket and the pressure line bracket. Tighten the fastener to 9 11.3 Nm (80-100 in. lbs.) (Fig. 2). 19. Install the fuel vapor canister. 20. Lower the vehicle. 21. Install the constant tension spring clamp removed in Step # 4 onto the rubber hose on the power steering return line. Slide the clamp so that it is 3 inches from the end of the rubber hose. 22. Push the end of the rubber hose portion of the power steering return line onto the power steering fluid reservoir suction port. Secure the hose by sliding the constant spring tension clamp installed on the hose in the last step, to within 6 mm (0.25 in.) of the end of the rubber hose. Be sure the hose clamp is installed past the bead on fluid reservoir fitting. 23. Check the vehicle production date. Was the vehicle built on or before September 13, 2004 (MDH 091344XX)? a. Yes » Go to "Replace Power Steering Hose - Step # 1". b. No » Go to "Steering/pump - Standard Procedure - Step # 1". REPLACE POWER STEERING HOSE: 1. Cut 850 mm (33.5 in.) of power steering hose (p/n 05135964AA) or equivalent. 2. Cut 790 mm (31 in.) of 15.9 mm (5/8 in.) or 17.5 mm (11/16 in.) convolute tubing. Place the convolute tubing around the power steering hose. 3. Open hood and remove the power steering reservoir cap. 4. Raise the vehicle on an appropriate hoist. 5. Locate the power steering cooler attached to the crossmember support. Remove the forward (closest to front of vehicle) hose from the cooler and tube. Drain the power steering fluid in an appropriate container. 6. Remove the two tension clamps from the removed hose and install on the new power steering return hose. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6788 7. Install the new hose and tension clamp onto the power steering cooler. 8. Wrap the hose clockwise around the perimeter and on top of the power steering cooler as shown in (Fig. 3). Install the hose and tension clamp to the power steering return tube. 9. Use two tie straps to strap the return hose to the power steering cooler and pressure steering hose shown in (Fig. 3). 10. Lower vehicle and open hood. 11. Proceed to "Steering/Pump - Standard Procedure". STEERING/PUMP - STANDARD PROCEDURE WARNING: FLUID LEVEL SHOULD BE CHECKED AND ADJUSTED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING ENGINE COMPONENTS. CAUTION: Use only Mopar(R) ATF+4 Automatic Transmission Fluid (MS-9602) in power steering system. Use of other Mopar(R) power steering fluids (MS5931 and MS9933) should be avoided to ensure peak performance of the power steering system under all operating conditions. Do not overfill. Read the fluid level through the side of the power steering fluid reservoir. The fluid level should be within "FILL RANGE" when the fluid is at a temperature of approximately 21°C to 27°C (70°F to 80°F). 1. Wipe the filler cap and area clean, then remove the cap. 2. Fill the fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 3. Start the engine and let run for a few seconds, then turn the engine off. 4. Add fluid if necessary. Repeat the above steps until the fluid level remains constant after running the engine. 5. Raise the front wheels off the ground. 6. Start the engine. 7. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6789 8. Add fluid if necessary. 9. Lower the vehicle, then turn the steering wheel slowly from lock-to-lock. 10. Stop the engine. Check the fluid level and refill as required. 11. If the fluid is extremely foamy, allow the vehicle to stabilize a few minutes, then repeat the above procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE: P8 New Part 68 Noisy Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 19-011-04 > Dec > 04 > Steering - Moaning Noise on Low Speed Turns Power Steering Fluid Cooler: All Technical Service Bulletins Steering - Moaning Noise on Low Speed Turns NUMBER: 19-011-04 GROUP: Steering DATE: December 7, 2004 SUBJECT: Moan/Fog Horn Like Sound While Turning During Slow Speed Or Parking Lot Maneuvers. OVERVIEW: This bulletin involves installing a finned power steering fluid cooler package and if necessary, a steering gear. MODELS: 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles built on or before September 13, 2004 (MDH 0913XX). SYMPTOM/CONDITION: The vehicle operator may describe a moan/fog horn like sound while turning during slow speed or parking lot maneuvers. The sound may occur throughout the steering range, off center, but not at the wheel stops. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: CAUTION: Throughout the following procedure, special care should be taken to prevent introducing contamination into the power steering system. 1. Open the hood. 2. Remove the cap from the power steering fluid reservoir. 3. Using a siphon pump/suction gun, remove as much power steering fluid as possible from the power steering fluid reservoir. 4. Remove and save the constant tension spring clamp securing the power steering return line hose to the power steering fluid reservoir. 5. Remove the rubber hose portion of the power steering return line from the power steering fluid reservoir fitting. 6. Drain the power steering fluid reservoir into an appropriate container. NOTE: This fluid should not be reused to avoid introducing contamination from the container. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 19-011-04 > Dec > 04 > Steering - Moaning Noise on Low Speed Turns > Page 6794 7. Raise the vehicle on an appropriate hoist. 8. Remove the fuel vapor canister. 9. Locate the bracket connecting the power steering return line cooler loop to the cradle reinforcement plate (Fig. 1). 10. Remove the fasteners connecting the cooler line to the reinforcement plate. Save the fasteners for use in Step # 17. 11. Locate the bracket connecting the power steering pressure line to the cradle reinforcement plate (Fig. 1). 12. Remove the fastener connecting the bracket to the reinforcement plate. Save the fastener for use in Step # 18. 13. Remove and discard the J/U nut clip on the bracket. 14. Locate and unscrew the tube nut connecting the power steering return line to the steering gear pinion housing. NOTE: The tube nut will remain loosely assembled to the power steering return line. 15. Drain the remaining fluid into an appropriate container and discard the loop cooler line that was removed from the vehicle. NOTE: This fluid should not be reused to avoid introducing contamination from the container. 16. Install the new power steering return line, p/n 04743473AE. Attach the power steering return line tube nut to the steering gear pinion housing and tighten to 27.1 - 35.0 N.m (240 - 310 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 19-011-04 > Dec > 04 > Steering - Moaning Noise on Low Speed Turns > Page 6795 17. Reuse the fastener removed in Step # 10. Install the fastener into the left weld nut on the cooler fin pack bracket and the left hole in the cradle reinforcement plate. Tighten the fastener to 9-11.3 Nm (80-100 in. lbs.) (Fig. 2). 18. Line up the pressure line bracket and the right weld nut in the cooler fin pack bracket. Reuse the fastener removed in Step # 12. Install the fastener through the right hole in the cradle reinforcement plate, the fin pack bracket and the pressure line bracket. Tighten the fastener to 9 11.3 N.m (80-100 in. lbs.) (Fig. 2). 19. Install the fuel vapor canister. 20. Lower the vehicle. 21. Install the constant tension spring clamp removed in Step # 4 onto the rubber hose on the power steering return line. Slide the clamp so that it is 3 inches from the end of the rubber hose. 22. Push the end of the rubber hose portion of the power steering return line onto the power steering fluid reservoir suction port. Secure the hose by sliding the constant spring tension clamp installed on the hose in the last step, to within 6 mm (0.25 in.) of the end of the rubber hose. Be sure the hose clamp is installed past the bead on fluid reservoir fitting. 23. Fill the power steering system. Refer to Steering/Pump - Standard Procedure at the end of this bulletin. 24. Test drive the vehicle in the parking lot. Determine if the sound, as describe in the Symptom/Condition section of this bulletin, is still present. 25. If the sound is no longer present. The repair is complete. If the sound is still present, replace the steering gear using the appropriate part number according to the Parts Required table above. Refer to the service information available in TechCONNECT. Refer to 19 - Steering/Gear Removal and Installation. 26. Fill the power steering system. Refer to Steering/Pump - Standard Procedure below. STEERING/PUMP - STANDARD PROCEDURE WARNING: FLUID LEVEL SHOULD BE CHECKED AND ADJUSTED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING ENGINE COMPONENTS. CAUTION: Use only Mopar(R) ATF+4 Automatic Transmission Fluid (MS-9602) in power steering system. Use of other Mopar(R) power steering fluids (M55931 and M59933) should be avoided to ensure peak performance of the power steering system under all operating conditions. Do not overfill. Read the fluid level through the side of the power steering fluid reservoir. The fluid level should be within "FILL RANGE" when the fluid is at a temperature of approximately 21 °C to 27°C (70°F to 80°F). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid Cooler: > 19-011-04 > Dec > 04 > Steering - Moaning Noise on Low Speed Turns > Page 6796 1. Wipe the filler cap and area clean, then remove the cap. 2. Fill the fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 3. Start the engine and let run for a few seconds, then turn the engine off. 4. Add fluid if necessary. Repeat the above steps until the fluid level remains constant after running the engine. 5. Raise the front wheels off the ground. 6. Start the engine. 7. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 8. Add fluid if necessary. 9. Lower the vehicle, then turn the steering wheel slowly from lock-to-lock. 10. Stop the engine. Check the fluid level and refill as required. 11. If the fluid is extremely foamy, allow the vehicle to stabilize a few minutes, then repeat the above procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Page 6797 Power Steering Fluid Cooler: Description and Operation FLUID COOLER DESCRIPTION Trailer Tow equipped vehicles are supplied with a cooler for the power steering system fluid. The power steering fluid cooler is located on the front suspension cradle crossmember reinforcement (Fig. 18). OPERATION The purpose of the power steering fluid cooler is to keep the temperature of the power steering system fluid from rising to a level that would affect the performance of the power steering system. The cooler used on this vehicle is referred to as a fluid-to-air type cooler. This means that the air flow across the tubes (and fines surrounding them) of the cooler is used to extract the heat from the cooler which it has absorbed from the power steering fluid flowing through it. The cooler is placed in the power steering fluid return line, between the steering gear and the power steering fluid reservoir. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Technical Service Bulletins > Page 6798 Power Steering Fluid Cooler: Service and Repair FLUID COOLER REMOVAL 1. Using a siphon pump, remove as much fluid as possible from the power steering fluid reservoir. 2. Raise vehicle. 3. Remove the hose clamps at the cooler and remove the hoses from the cooler inlet and outlet tubes. 4. Remove the 2 bolts attaching the power steering cooler cradle crossmember reinforcement (Fig. 19). Remove the cooler. INSTALLATION 1. Install the power steering fluid cooler on the cradle crossmember reinforcement (Fig. 19). Install the mounting bolts and tighten to 11 Nm (100 inch lbs.). 2. Install power steering fluid hoses on the cooler. Be sure hose clamps are installed on hose past the upset bead on the power steering cooler tubes. 3. Lower the vehicle to a point where front tires are just off the ground. 4. Perform Power Steering Pump Initial Operation procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Description and Operation Power Steering Fluid Reservoir: Description and Operation RESERVOIR - POWER STEERING FLUID DESCRIPTION - 2.4L/3.3L/3.8L ENGINE All vehicles use a remote mounted power steering fluid reservoir. The power steering fluid reservoir is mounted to the engine near the battery (Fig. 25). OPERATION The power steering fluid reservoir stores and supplies power steering fluid for the power steering system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Description and Operation > Page 6802 Power Steering Fluid Reservoir: Service and Repair RESERVOIR - POWER STEERING FLUID REMOVAL - 3.3L/3.8L ENGINE 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from power steering fluid reservoir. 3. Open retainer on side of reservoir and remove cables from retainer. 4. Remove clamp attaching supply hose to power steering fluid reservoir. Disconnect hose from reservoir (Fig. 22). 5. Remove clamp attaching return hose to power steering fluid reservoir. Disconnect hose from reservoir (Fig. 22). 6. Remove bolts and nut securing reservoir in place (Fig. 22). 7. Remove reservoir. INSTALLATION 1. Place reservoir into place on engine (Fig. 22). 2. Install reservoir mounting bolts and nut (Fig. 22). Tighten fasteners to 12 Nm (105 inch lbs.) torque. 3. Install supply hose onto reservoir (Fig. 22). Slide the hose clamp into position on fluid reservoir and attach it. Be sure hose clamp in installed past bead on fluid reservoir fitting. 4. Install return hose onto reservoir (Fig. 22). Slide the hose clamp into position on fluid reservoir and attach it. Be sure hose clamp in installed past bead on fluid reservoir fitting. 5. Fill and bleed power steering system using Power Steering Pump Initial Operation Procedure. 6. Inspect system for leaks. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder Power Steering Line/Hose: Customer Interest Steering - Low Speed Steering Shudder NUMBER: 19-006-05 GROUP: Steering DATE: August 4, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-004-03, DATED AUGUST 29, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Steering Shudder OVERVIEW: This bulletin involves replacing one of the two power steering cooler hoses with a new longer power steering hose and if necessary, installing a fin packed power steering cooler. MODELS: 2001 - 2005 (RS) Town & Country, Caravan, Voyager 2001 - 2005 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to right hand and left hand drive vehicles equipped with a 3.3L or 3.8L engine (sales code EGA, EGM, EGH) built on or before December 8, 2004 (MDH 1208XX) SYMPTOM/CONDITION: A shudder (vibration) is felt inside the vehicle while turning the steering wheel at idle or during low speeds such as a parking lot maneuver. The shudder may be felt in the steering wheel, seat, and/or body. DIAGNOSIS: 1. Verify the condition: - Perform stationary turns and/or low speed turns in drive and reverse. Perform the evaluation with the A/C in the on and off position. Is steering shudder detected? a. Yes » Go to Step # 2. b. No» Further diagnosis is needed, this bulletin does not apply. 2. Inspect for the presence of a power steering finned cooler. Is a finned cooler present? a. Yes » Go to "Replace Power Steering Hose - Step # 1". b. No. » Go to "Install Finned Cooler - Step # 1". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6811 PARTS REQUIRED INSTALL FINNED COOLER: CAUTION: Throughout the following procedure, special care should be taken to prevent introducing contamination into the power steering system. 1. Open the hood. 2. Remove the cap from the power steering fluid reservoir. 3. Using a siphon pump/suction gun, remove as much power steering fluid as possible from the power steering fluid reservoir. 4. Remove and save the constant tension spring clamp securing the power steering return line hose to the power steering fluid reservoir. 5. Remove the rubber hose portion of the power steering return line from the power steering fluid reservoir fitting. 6. Drain the power steering fluid reservoir into an appropriate container. NOTE: This fluid should not be reused to avoid introducing contamination from the container. 7. Raise the vehicle on an appropriate hoist. 8. Remove the fuel vapor canister. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6812 9. Locate the bracket connecting the power steering return line cooler loop to the cradle reinforcement plate (Fig. 1). 10. Remove the fasteners connecting the cooler line to the reinforcement plate. Save the fasteners for use in Step # 17. 11. Locate the bracket connecting the power steering pressure line to the cradle reinforcement plate (Fig. 1). 12. Remove the fastener connecting the bracket to the reinforcement plate. Save the fastener for use in Step # 18. 13. Remove and discard the J/U nut clip on the bracket. 14. Locate and unscrew the tube nut connecting the power steering return line to the steering gear pinion housing. NOTE: The tube nut will remain loosely assembled to the power steering return line. 15. Drain the remaining fluid into an appropriate container and discard the loop cooler line that was removed from the vehicle. NOTE: This fluid should not be reused to avoid introducing contamination from the container. 16. Install the new power steering return line, p/n 04743473AE. Attach the power steering return line tube nut to the steering gear pinion housing and tighten to 27.1 - 35.0 Nm (240 - 310 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6813 17. Reuse the fastener removed in Step # 10. Install the fastener into the left weld nut on the cooler fin pack bracket and the left hole in the cradle reinforcement plate. Tighten the fastener to 9 - 11.3 Nm (80-100 in. lbs.) (Fig. 2). 18. Line up the pressure line bracket and the right weld nut in the cooler fin pack bracket. Reuse the fastener removed in Step # 12. Install the fastener through the right hole in the cradle reinforcement plate, the fin pack bracket and the pressure line bracket. Tighten the fastener to 9 11.3 Nm (80-100 in. lbs.) (Fig. 2). 19. Install the fuel vapor canister. 20. Lower the vehicle. 21. Install the constant tension spring clamp removed in Step # 4 onto the rubber hose on the power steering return line. Slide the clamp so that it is 3 inches from the end of the rubber hose. 22. Push the end of the rubber hose portion of the power steering return line onto the power steering fluid reservoir suction port. Secure the hose by sliding the constant spring tension clamp installed on the hose in the last step, to within 6 mm (0.25 in.) of the end of the rubber hose. Be sure the hose clamp is installed past the bead on fluid reservoir fitting. 23. Check the vehicle production date. Was the vehicle built on or before September 13, 2004 (MDH 091344XX)? a. Yes » Go to "Replace Power Steering Hose - Step # 1". b. No » Go to "Steering/pump - Standard Procedure - Step # 1". REPLACE POWER STEERING HOSE: 1. Cut 850 mm (33.5 in.) of power steering hose (p/n 05135964AA) or equivalent. 2. Cut 790 mm (31 in.) of 15.9 mm (5/8 in.) or 17.5 mm (11/16 in.) convolute tubing. Place the convolute tubing around the power steering hose. 3. Open hood and remove the power steering reservoir cap. 4. Raise the vehicle on an appropriate hoist. 5. Locate the power steering cooler attached to the crossmember support. Remove the forward (closest to front of vehicle) hose from the cooler and tube. Drain the power steering fluid in an appropriate container. 6. Remove the two tension clamps from the removed hose and install on the new power steering return hose. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6814 7. Install the new hose and tension clamp onto the power steering cooler. 8. Wrap the hose clockwise around the perimeter and on top of the power steering cooler as shown in (Fig. 3). Install the hose and tension clamp to the power steering return tube. 9. Use two tie straps to strap the return hose to the power steering cooler and pressure steering hose shown in (Fig. 3). 10. Lower vehicle and open hood. 11. Proceed to "Steering/Pump - Standard Procedure". STEERING/PUMP - STANDARD PROCEDURE WARNING: FLUID LEVEL SHOULD BE CHECKED AND ADJUSTED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING ENGINE COMPONENTS. CAUTION: Use only Mopar(R) ATF+4 Automatic Transmission Fluid (MS-9602) in power steering system. Use of other Mopar(R) power steering fluids (MS5931 and MS9933) should be avoided to ensure peak performance of the power steering system under all operating conditions. Do not overfill. Read the fluid level through the side of the power steering fluid reservoir. The fluid level should be within "FILL RANGE" when the fluid is at a temperature of approximately 21°C to 27°C (70°F to 80°F). 1. Wipe the filler cap and area clean, then remove the cap. 2. Fill the fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 3. Start the engine and let run for a few seconds, then turn the engine off. 4. Add fluid if necessary. Repeat the above steps until the fluid level remains constant after running the engine. 5. Raise the front wheels off the ground. 6. Start the engine. 7. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6815 8. Add fluid if necessary. 9. Lower the vehicle, then turn the steering wheel slowly from lock-to-lock. 10. Stop the engine. Check the fluid level and refill as required. 11. If the fluid is extremely foamy, allow the vehicle to stabilize a few minutes, then repeat the above procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE: P8 New Part 68 Noisy Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder Power Steering Line/Hose: All Technical Service Bulletins Steering - Low Speed Steering Shudder NUMBER: 19-006-05 GROUP: Steering DATE: August 4, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-004-03, DATED AUGUST 29, 2003, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Steering Shudder OVERVIEW: This bulletin involves replacing one of the two power steering cooler hoses with a new longer power steering hose and if necessary, installing a fin packed power steering cooler. MODELS: 2001 - 2005 (RS) Town & Country, Caravan, Voyager 2001 - 2005 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to right hand and left hand drive vehicles equipped with a 3.3L or 3.8L engine (sales code EGA, EGM, EGH) built on or before December 8, 2004 (MDH 1208XX) SYMPTOM/CONDITION: A shudder (vibration) is felt inside the vehicle while turning the steering wheel at idle or during low speeds such as a parking lot maneuver. The shudder may be felt in the steering wheel, seat, and/or body. DIAGNOSIS: 1. Verify the condition: - Perform stationary turns and/or low speed turns in drive and reverse. Perform the evaluation with the A/C in the on and off position. Is steering shudder detected? a. Yes » Go to Step # 2. b. No» Further diagnosis is needed, this bulletin does not apply. 2. Inspect for the presence of a power steering finned cooler. Is a finned cooler present? a. Yes » Go to "Replace Power Steering Hose - Step # 1". b. No. » Go to "Install Finned Cooler - Step # 1". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6821 PARTS REQUIRED INSTALL FINNED COOLER: CAUTION: Throughout the following procedure, special care should be taken to prevent introducing contamination into the power steering system. 1. Open the hood. 2. Remove the cap from the power steering fluid reservoir. 3. Using a siphon pump/suction gun, remove as much power steering fluid as possible from the power steering fluid reservoir. 4. Remove and save the constant tension spring clamp securing the power steering return line hose to the power steering fluid reservoir. 5. Remove the rubber hose portion of the power steering return line from the power steering fluid reservoir fitting. 6. Drain the power steering fluid reservoir into an appropriate container. NOTE: This fluid should not be reused to avoid introducing contamination from the container. 7. Raise the vehicle on an appropriate hoist. 8. Remove the fuel vapor canister. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6822 9. Locate the bracket connecting the power steering return line cooler loop to the cradle reinforcement plate (Fig. 1). 10. Remove the fasteners connecting the cooler line to the reinforcement plate. Save the fasteners for use in Step # 17. 11. Locate the bracket connecting the power steering pressure line to the cradle reinforcement plate (Fig. 1). 12. Remove the fastener connecting the bracket to the reinforcement plate. Save the fastener for use in Step # 18. 13. Remove and discard the J/U nut clip on the bracket. 14. Locate and unscrew the tube nut connecting the power steering return line to the steering gear pinion housing. NOTE: The tube nut will remain loosely assembled to the power steering return line. 15. Drain the remaining fluid into an appropriate container and discard the loop cooler line that was removed from the vehicle. NOTE: This fluid should not be reused to avoid introducing contamination from the container. 16. Install the new power steering return line, p/n 04743473AE. Attach the power steering return line tube nut to the steering gear pinion housing and tighten to 27.1 - 35.0 Nm (240 - 310 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6823 17. Reuse the fastener removed in Step # 10. Install the fastener into the left weld nut on the cooler fin pack bracket and the left hole in the cradle reinforcement plate. Tighten the fastener to 9 - 11.3 Nm (80-100 in. lbs.) (Fig. 2). 18. Line up the pressure line bracket and the right weld nut in the cooler fin pack bracket. Reuse the fastener removed in Step # 12. Install the fastener through the right hole in the cradle reinforcement plate, the fin pack bracket and the pressure line bracket. Tighten the fastener to 9 11.3 Nm (80-100 in. lbs.) (Fig. 2). 19. Install the fuel vapor canister. 20. Lower the vehicle. 21. Install the constant tension spring clamp removed in Step # 4 onto the rubber hose on the power steering return line. Slide the clamp so that it is 3 inches from the end of the rubber hose. 22. Push the end of the rubber hose portion of the power steering return line onto the power steering fluid reservoir suction port. Secure the hose by sliding the constant spring tension clamp installed on the hose in the last step, to within 6 mm (0.25 in.) of the end of the rubber hose. Be sure the hose clamp is installed past the bead on fluid reservoir fitting. 23. Check the vehicle production date. Was the vehicle built on or before September 13, 2004 (MDH 091344XX)? a. Yes » Go to "Replace Power Steering Hose - Step # 1". b. No » Go to "Steering/pump - Standard Procedure - Step # 1". REPLACE POWER STEERING HOSE: 1. Cut 850 mm (33.5 in.) of power steering hose (p/n 05135964AA) or equivalent. 2. Cut 790 mm (31 in.) of 15.9 mm (5/8 in.) or 17.5 mm (11/16 in.) convolute tubing. Place the convolute tubing around the power steering hose. 3. Open hood and remove the power steering reservoir cap. 4. Raise the vehicle on an appropriate hoist. 5. Locate the power steering cooler attached to the crossmember support. Remove the forward (closest to front of vehicle) hose from the cooler and tube. Drain the power steering fluid in an appropriate container. 6. Remove the two tension clamps from the removed hose and install on the new power steering return hose. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6824 7. Install the new hose and tension clamp onto the power steering cooler. 8. Wrap the hose clockwise around the perimeter and on top of the power steering cooler as shown in (Fig. 3). Install the hose and tension clamp to the power steering return tube. 9. Use two tie straps to strap the return hose to the power steering cooler and pressure steering hose shown in (Fig. 3). 10. Lower vehicle and open hood. 11. Proceed to "Steering/Pump - Standard Procedure". STEERING/PUMP - STANDARD PROCEDURE WARNING: FLUID LEVEL SHOULD BE CHECKED AND ADJUSTED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING ENGINE COMPONENTS. CAUTION: Use only Mopar(R) ATF+4 Automatic Transmission Fluid (MS-9602) in power steering system. Use of other Mopar(R) power steering fluids (MS5931 and MS9933) should be avoided to ensure peak performance of the power steering system under all operating conditions. Do not overfill. Read the fluid level through the side of the power steering fluid reservoir. The fluid level should be within "FILL RANGE" when the fluid is at a temperature of approximately 21°C to 27°C (70°F to 80°F). 1. Wipe the filler cap and area clean, then remove the cap. 2. Fill the fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 3. Start the engine and let run for a few seconds, then turn the engine off. 4. Add fluid if necessary. Repeat the above steps until the fluid level remains constant after running the engine. 5. Raise the front wheels off the ground. 6. Start the engine. 7. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-006-05 > Aug > 05 > Steering - Low Speed Steering Shudder > Page 6825 8. Add fluid if necessary. 9. Lower the vehicle, then turn the steering wheel slowly from lock-to-lock. 10. Stop the engine. Check the fluid level and refill as required. 11. If the fluid is extremely foamy, allow the vehicle to stabilize a few minutes, then repeat the above procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE: P8 New Part 68 Noisy Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure Power Steering Line/Hose: Service and Repair Hose - Pressure HOSE - POWER STEERING PRESSURE REMOVAL - 3.3L/3.8L ENGINE NOTE: Before proceeding, review all WARNINGS and CAUTIONS. 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from power steering fluid reservoir. 3. Raise vehicle. 4. Remove front emissions vapor canister. 5. Remove two bolts securing pressure hose routing clamps to suspension cradle crossmember and steel reinforcement (Fig. 21). 6. Place an oil drain pan under vehicle to catch draining power steering fluid. 7. Disconnect pressure hose at power steering gear (Fig. 21). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 6828 8. Remove pressure hose routing bracket bolt at engine (Fig. 22). Bolt can be accessed through hole in cradle crossmember (Fig. 23). 9. Disconnect pressure hose tube nut at power steering pump (Fig. 22). 10. Remove power steering fluid pressure hose from vehicle. INSTALLATION 1. Remove any used O-rings from ends of power steering hose. 2. Using a lint free towel, wipe clean hose ends, power steering pump pressure outlet fitting and steering gear port. 3. Install new O-rings on ends of power steering fluid pressure hose. Lubricate O-rings using clean power steering fluid. CAUTION: Use care not to bend tube ends of the power steering hoses when installing. Leaks and restrictions may occur. CAUTION: Power steering fluid hoses must remain away from the exhaust system and must not come in contact with any unfriendly surfaces on the vehicle. 4. Route hose up behind engine toward pump avoiding tight bends or kinking. 5. Install power steering pressure hose end into pump pressure outlet fitting (Fig. 22). Thread tube nut into outlet fitting, but do not tighten at this Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 6829 time. 6. Attach pressure hose routing bracket to engine (Fig. 22). Tighten bolt to 23 Nm (200 inch lbs.) torque. 7. Tighten hose tube nut at pump outlet fitting to 31 Nm (275 inch lbs.) torque. 8. Route hose behind cradle crossmember and start hose end into gear port. Do not tighten hose tube nut at this time. 9. Attach hose to suspension cradle crossmember and steel reinforcement using two routing clamps and bolts (Fig. 21). Tighten clamp bolt at steel reinforcement to 11 Nm (100 inch lbs.) torque. Tighten clamp bolt at cradle crossmember to 23 Nm (200 inch lbs.) torque. 10. Tighten hose tube nut at power steering gear port to 31 Nm (275 inch lbs.) torque. 11. Install front emissions vapor canister. 12. Lower vehicle. 13. Fill and bleed the power steering system using the Power Steering Pump Initial Operation Procedure. 14. Inspect system for leaks. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 6830 Power Steering Line/Hose: Service and Repair Hose - Return HOSE - POWER STEERING RETURN REMOVAL - 3.3L/3.8L ENGINE NOTE: Before proceeding, review all WARNINGS and CAUTIONS. 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from power steering fluid reservoir. 3. Place an oil drain pan under vehicle to catch any draining power steering fluid. 4. Remove clamp attaching return hose to power steering fluid reservoir. Disconnect hose from reservoir (Fig. 22). 5. Follow return hose downward and open retainer at ABS bracket (Fig. 21). Remove hose tube from retainer. 6. Raise vehicle. 7. Remove front emissions vapor canister. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 6831 8. Remove bolt securing return hose routing clamp to suspension cradle crossmember (Fig. 21). 9. Remove 2 bolts attaching power steering cooler to cradle crossmember reinforcement (Fig. 24). 10. Disconnect return hose at power steering gear (Fig. 21). 11. Remove power steering fluid return hose with cooler from vehicle. INSTALLATION 1. Remove any used O-rings from ends of power steering hose. 2. Using a lint free towel, wipe clean hose ends and power steering gear hose port. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 6832 3. Install a new O-ring on gear port end of power steering fluid hose. Lubricate O-ring using clean power steering fluid. CAUTION: Use care not to bend tube ends of the power steering hoses when installing. Leaks and restrictions may occur. CAUTION: Power steering fluid hoses must remain away from the exhaust system and must not come in contact with any unfriendly surfaces on the vehicle. 4. Route hose (with cooler attached) up toward reservoir avoiding tight bends or kinking. 5. Start steering gear end of hose into gear port. Do not tighten hose tube nut at this time. 6. Attach return hose tubes to suspension cradle crossmember using routing clamp and bolt (Fig. 21). Tighten clamp bolt to 23 Nm (200 inch lbs.) torque. 7. Install the power steering fluid cooler on the cradle crossmember reinforcement (Fig. 24). Install the mounting bolts and tighten to 11 Nm (100 inch lbs.). When installing mounting bolts, include pressure hose routing clamp. 8. Tighten hose tube nut at power steering gear port to 31 Nm (275 inch lbs.) torque. 9. Install front emissions vapor canister. 10. Lower vehicle. 11. Install return hose tube into retainer on ABS bracket (Fig. 21). Close the bracket. 12. Install return hose onto reservoir (Fig. 22). Slide the hose clamp into position on fluid reservoir and attach it. Be sure hose clamp in installed past bead on fluid reservoir fitting. 13. Fill and bleed power steering system using the Power Steering Pump Initial Operation Procedure. 14. Inspect system for leaks. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Hose - Pressure > Page 6833 Power Steering Line/Hose: Service and Repair Hose - Supply HOSE - POWER STEERING SUPPLY REMOVAL - 3.3L/3.8L ENGINE NOTE: Before proceeding, review all WARNINGS and CAUTIONS. 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much power steering fluid as possible from power steering fluid reservoir. 3. Place an oil drain pan under vehicle to catch any draining power steering fluid. 4. Remove clamp attaching supply hose to power steering fluid reservoir. Disconnect hose from reservoir (Fig. 22). 5. Pull upward on hose routing clip releasing it from bracket on cylinder head cover (Fig. 22). NOTE: It may be necessary to remove air cleaner housing to gain greater access to supply hose at power steering pump. 6. Remove clamp attaching supply hose to power steering pump. Disconnect hose from pump and remove from vehicle (Fig. 22). INSTALLATION 1. Install supply hose onto supply fitting on power steering pump (Fig. 22). Slide the hose clamp into position on fluid reservoir and attach it. Be sure hose clamp in installed past bead on fluid reservoir fitting. 2. Align routing clip located toward center of supply hose with hole in bracket on cylinder head cover and push into place (Fig. 22). 3. Install supply hose onto reservoir (Fig. 22). Slide the hose clamp into position on fluid reservoir and attach it. Be sure hose clamp in installed past bead on fluid reservoir fitting. 4. Fill and bleed power steering system using Power Steering Pump Initial Operation Procedure. 5. Inspect system for leaks. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service Precautions Power Steering Pump: Service Precautions WARNING WARNING: POWER STEERING FLUID, ENGINE PARTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION CAUTION: When the system is open, cap all open ends of the hoses, power steering pump fittings or power steering gear ports to prevent entry of foreign material into the components. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service Precautions > Page 6837 Power Steering Pump: Description and Operation DESCRIPTION - PUMP (2.4L/3.3L/3.8L ENGINE) Hydraulic pressure for the operation of the power steering gear is provided by a belt driven power steering pump. The power steering pump is mounted on the back side of the engine on all engine applications. The pumps are different depending on the engine option. The pump for the 2.4L engine is made out of cast iron and steel (Fig. 1). The pump used on the 3.3L/3.8L engine is made of aluminum (Fig. 2). The pump for the 3.3L/3.8L engine does not have a return fitting as the pump for the 2.4L engine does. The power steering return hose on the 3.3L/3.8L engine goes to the reservoir instead of the pump. OPERATION The power steering pump is a constant displacement vane type pump. The 2.4L pump has an integral fluid reservoir and there is a secondary remote non-flow reservoir which acts only as a fluid fill and check point. The 3.3L/3.8L pump houses very little fluid and is therefore supplied by a remote flow through reservoir. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Initial Operation Power Steering Pump: Service and Repair Initial Operation STANDARD PROCEDURE - POWER STEERING PUMP INITIAL OPERATION WARNING: FLUID LEVEL SHOULD BE CHECKED AND ADJUSTED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING ENGINE COMPONENTS. CAUTION: Use only Mopar ATF+4 Automatic Transmission Fluid (MS-9602) in power steering system. Use of other Mopar power steering fluids (MS5931 and MS9933) should be avoided to ensure peak performance of the power steering system under all operating conditions. Do not overfill. Read the fluid level through the side of the power steering fluid reservoir. The fluid level should be within "FILL RANGE" when the fluid is at a temperature of approximately 21°C to 27°C (70°F to 80°F). 1. Wipe the filler cap and area clean, then remove the cap. 2. Fill the fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 3. Start the engine and let run for a few seconds, then turn the engine off. 4. Add fluid if necessary. Repeat the above steps until the fluid level remains constant after running the engine. 5. Raise the front wheels off the ground. 6. Start the engine. 7. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 8. Add fluid if necessary. 9. Lower the vehicle, then turn the steering wheel slowly from lock-to-lock. 10. Stop the engine. Check the fluid level and refill as required. 11. If the fluid is extremely foamy, allow the vehicle to stabilize a few minutes, then repeat the above procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Initial Operation > Page 6840 Power Steering Pump: Service and Repair Removal and Installation PUMP (3.3L/3.8L ENGINE) REMOVAL 1. Remove the (-) negative battery cable from the battery and isolate cable. 2. Remove the wiper module (unit). 3. Raise the vehicle. 4. Remove the drive belt splash shield. 5. Remove the pressure hose routing bracket bolt (Fig. 9). 6. lower the vehicle. 7. Remove cap from power steering fluid reservoir. 8. Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. 9. Disconnect the pressure hose from the pump (Fig. 10). 10. Disconnect the fluid supply hose from the pump (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Initial Operation > Page 6841 11. Remove the three front mounting bolts through the pulley (Fig. 11) 12. Remove the pump (with pulley) through the engine compartment rocking it over the aluminum bracket. DISASSEMBLY - PUMP (PULLEY) The only serviceable part of the power steering pump is the pulley. The procedure following is for removal and installation of the pulley from the pump once the pump is removed from the vehicle. 1. Remove the power steering pump from the vehicle. 2. Remove the pulley from the shaft of the power steering pump using Puller C-4333 (Fig. 14). CAUTION: Do not hammer on power steering pump pulley. This will damage the pulley and the power steering pump. 3. Replace pulley if it is found to be bent, cracked, or loose. ASSEMBLY - PUMP (PULLEY) The only serviceable part of the power steering pump is the pulley. The procedure following is for removal and installation of the pulley from the pump once the pump is removed from the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Initial Operation > Page 6842 1. Install the pulley with Installer C-4063 (Fig. 15). Do not use the tool adapters. 2. Ensure that the tool and the pulley remain aligned with the pump shaft. Prevent the pulley from being cocked on the shaft. 3. Install the pulley until it is flush with the end of the power steering pump shaft (Fig. 16). 4. Install the power steering pump on the vehicle. INSTALLATION 1. Install power steering pump back in vehicle using the reverse order of its removal through the engine compartment of the vehicle. 2. Install the power steering pump on its mounting bracket. 3. Install the 3 front power steering pump mounting bolts (Fig. 11). Tighten the 3 front power steering pump mounting bolts to a torque of 54 Nm (40 ft. lbs.). NOTE: Before installing power steering pressure hose on power steering pump, inspect the O-ring on the power steering pressure hose for damage and replace if required. 4. Install the power steering fluid pressure line into the pressure output fitting of the power steering pump (Fig. 10). Do not fully tighten tube nut at this time. 5. Install the power steering fluid supply hose on the power steering pump supply fitting (Fig. 10). Be sure hose clamp is properly installed. 6. Raise the vehicle. 7. Install the routing clip on the engine for the pressure hose (Fig. 9) and tighten fastener. 8. Install the serpentine drive belt. 9. Install the drive belt splash shield. 10. Lower the vehicle. 11. Tighten the pressure line to pump pressure fitting tube nut to a torque of 31 Nm (275 inch lbs.). 12. Install the wiper module (unit). 13. Connect the negative battery cable on the negative battery post. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Initial Operation > Page 6843 14. Fill and bleed the power steering system using the Power Steering Pump Initial Operation Procedure. 15. Inspect for leaks. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Page 6844 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 6850 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 6851 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Page 6852 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Lower Steering Column Cover Steering Column Cover: Service and Repair Lower Steering Column Cover REMOVAL Steering Column Cover And End Cap 1. Use trim stick to gently pry rt edge of steering column cover from lower rt panel just enough to disengage 'belt loops'. 2. Pull lower steering column cover rearward to release spring clips and remove from the vehicle. 3. Remove the three screws attaching the end cap to instrument panel. 4. Pull end cap outward to release spring clips and remove from the vehicle INSTALLATION 1. Place the end cap into position and push spring clips into position. 2. Attach left side of lower steering column cover first. Align locating ribs into left end cap and rock cover to right side and align belt loops into position into instrument lower right panel. 3. Place the lower steering column cover into position and push spring clips into position. 4. Install the two screws attaching the lower steering column cover to instrument panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Service and Repair > Lower Steering Column Cover > Page 6857 Steering Column Cover: Service and Repair Over Steering Column Cover REMOVAL Over Steering Column Cover 1. Taking a firm grasp of the over steering column cover front edge, give a quick upward pulling motion to disengage the cover from the instrument panel. 2. Remove the over steering column cover from the vehicle. INSTALLATION 1. Place the over steering column cover into position over the retaining slots and firmly snap into place. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-001-05 > Jan > 05 > Steering Steering Wheel Tilt Mechanism Inoperative Technical Service Bulletin # 19-001-05 Date: 050126 Steering - Steering Wheel Tilt Mechanism Inoperative NUMBER: 19-001-05 GROUP: Steering DATE: January 26, 2005 SUBJECT: Steering Wheel Tilt Mechanism Inoperative OVERVIEW: This bulletin involves placing a mastic patch over the eyelet of the steering wheel tilt mechanism linkage. MODELS: 2004 - 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager 2005 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to Left Hand Drive vehicles only. SYMPTOM/CONDITION: The vehicle operator may experience the steering wheel tilt mechanism is inoperative. DIAGNOSIS: 1. Pull on the tilt release lever to tilt the steering wheel then try and raise or lower the wheel depending on the steering wheel position. 2. If the steering wheel cannot be moved: a. CS vehicles, proceed to CS Repair Procedure: Step # 1. b. RS/RG vehicles, proceed to RS/RG Repair Procedure Step # 1. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-001-05 > Jan > 05 > Steering Steering Wheel Tilt Mechanism Inoperative > Page 6866 Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. RS/RS Procedure 1. Disconnect and isolate the negative (ground) cable from the battery. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the "Over Steering Column Bezel" by lifting it straight up with a firm pull (not shown). 3. Remove the upper shroud mounting screws. Using your hands on each side of the column, gently press inward at the seams between the two shrouds at points of contact to disengage the inner locking tabs, then remove the upper shroud. If the vehicle is equipped with traction control, the lower shroud will need to be removed once the upper shroud is unfastened in order to disconnect the traction control wiring connector and remove the upper shroud with the traction control switch intact (Fig. 1). 4. If equipped with adjustable pedals, disconnect the wiring connector for the switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-001-05 > Jan > 05 > Steering Steering Wheel Tilt Mechanism Inoperative > Page 6867 5. Remove the lower shroud mounting screw, then remove the lower shroud (Fig. 2). 6. If equipped with traction control, disconnect the wiring connector from the column wiring harness. Remove the upper shroud with the traction control switch. 7. Remove the screws fastening the fixed shroud in place. Remove the fixed shroud (Fig. 3). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-001-05 > Jan > 05 > Steering Steering Wheel Tilt Mechanism Inoperative > Page 6868 8. Using locking pliers rotate the tube of the Rotary Tilt Mechanism (RTA) clockwise looking from the steering wheel providing maximum slack in the cable, be careful not to damage the tube (Fig. 4). NOTE: Continue holding the RTA in this position through Step 10. 9. With the other hand place the ball of the cable into the eyelet of the tilt release lever linkage. Push the ball down into the opening until it locks into place (Fig. 5). 10. Rotate the tube counter-clock wise, then release the pliers holding the tube of the RTA. 11. Wipe any excessive grease from the top of the linkage between the hole and the ball. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-001-05 > Jan > 05 > Steering Steering Wheel Tilt Mechanism Inoperative > Page 6869 12. Center and apply mastic patch (3/4" x 1") about 1-3 mm (0.04- 0.12 in.) from the rivet on linkage, over the hole and around the forward most part of the linkage (Fig. 6). 13. Firmly press down on the mastic patch and hold for 5 seconds. 14. Firmly press the mastic onto the forward edge of the linkage and hold for 5 seconds, then go around edges of the mastic making sure they are secured to the linkage. 15. Install the fixed shroud. Install the screws fastening the fixed shroud in place and tighten the screws to 3 N.m (23 in. lbs.) torque (Fig. 3). 16. If equipped with traction control, position the upper shroud above the column and route the switch wiring down around the column. Connect the wiring connector from the column wiring harness to the traction control switch wiring (attached to upper shroud). 17. Position the lower shroud on the column. Install the lower shroud mounting screw. Tighten the screw to 2 N.m (17 in.lbs.) torque (Fig. 2) 18. If equipped with adjustable pedals, connect the wiring connector for the switch to the column wiring harness. 19. Position the upper shroud on top of the lower shroud and snap it into place. Install the upper shroud mounting screws. Tighten the screws to 2 N.m (17 in.lbs.) torque (Fig. 1). 20. Inspect shroud mating surfaces for excessive gaps and correct as necessary. 21. Install the "Over Steering Column Bezel" by positioning it over the retaining slots and firmly snapping it into place. 22. Connect the battery negative (ground) cable to battery post following special Diagnosis And Testing procedure. Refer to the service information available in TechCONNECT. Reference: Service Info, 8 - Electrical/Restraints - Diagnosis And Testing. WARNING: Failure to connect the battery properly could result in personal injury or death. 23. Reset the clock to the proper time. 24. Verify the vehicle and system operation. 25. Close the hood. CS Repair Procedure 1. Disconnect and isolate the negative (ground) cable from the battery. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-001-05 > Jan > 05 > Steering Steering Wheel Tilt Mechanism Inoperative > Page 6870 2. Remove the steering column opening cover retaining screws and unsnap the cover from instrument panel (Fig. 7). 3. Remove four knee blocker airbag retaining bolts from airbag (Fig. 8). 4. Pull down knee blocker airbag and disconnect the one electrical connector (Fig. 8). 5. Remove knee blocker airbag from vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-001-05 > Jan > 05 > Steering Steering Wheel Tilt Mechanism Inoperative > Page 6871 6. Remove three screws fastening lower shroud to upper shroud and column (Fig. 9). 7. Remove the four nuts fastening column to dash (Fig. 10). 8. Carefully lower the steering column resting the steering wheel on the seat. 9. Using your hands, gently press inward at the seams between the shrouds at the points where the inner locking tabs exist, unlocking the tabs (Fig. 9). 10. Remove the upper, then lower shroud. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-001-05 > Jan > 05 > Steering Steering Wheel Tilt Mechanism Inoperative > Page 6872 11. Using locking pliers rotate the tube of the Rotary Tilt Mechanism (RTA) clockwise looking from the steering wheel providing maximum slack in the cable, be careful not to damage tube (Fig. 4). NOTE: Continue holding the RTA in this position through Step 13. 12. With the other hand place the ball of the cable into the eyelet of the tilt release lever linkage. Push the ball down into the opening until it locks into place (Fig. 5). 13. Rotate the tube counter-clockwise, then release the pliers holding the tube of the RTA. 14. Wipe any excessive grease from the top of the linkage between the hole and the ball. 15. Center and apply a mastic patch (3/4" x 1") about 1-3 mm from the rivet on linkage, over the hole and around the forward most part of the linkage (Fig. 6). 16. Firmly press down on the mastic patch and hold for 5 seconds. 17. Firmly press the mastic onto the forward edge of the linkage and hold for 5 seconds, then go around the edges of the mastic making sure they are secured to the linkage. 18. Install the upper and lower shroud. 19. Snap the shrouds together at the locking tab locations on both sides. NOTE: The screws securing the shrouds will be installed later as part of Step # 22. 20. Raise the steering column into place and loosely install the four nuts. Tighten the four nuts to 12 N.m (105 in.lbs.) torque. 21. Install the center mounting screw securing the lower shroud to the column. Tighten the screw to 2 N.m (18 in.lbs.) torque. 22. Install the two outer mounting screws securing the lower shroud to the upper shroud. Tighten the screws to 2 N.m (18 in. lbs.) torque. 23. Inspect the shroud mating surfaces for excessive gaps and adjust as necessary. 24. Place the knee blocker airbag into position in the instrument panel opening. 25. Connect the electrical connector (Fig. 8). 26. Install the four knee blocker airbag retaining bolts and secure the knee blocker airbag in place (Fig. 8). 27. Position the steering column opening cover over the retaining slots and firmly snap into place. Install the two retaining screws (Fig. 7). 28. Connect the battery negative (ground) cable to battery post following special Diagnosis And Testing procedure. Refer to the service information available in TechCONNECT. Reference: Service Info, 8 - Electrical/Restraints - Diagnosis And Testing. WARNING: Failure to connect the battery properly could result in personal injury or death. 29. Reset the clock to the proper time. 30. Verify the vehicle and system operation. 31. Close the hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-001-05 > Jan > 05 > Steering - Steering Wheel Tilt Mechanism Inoperative Technical Service Bulletin # 19-001-05 Date: 050126 Steering - Steering Wheel Tilt Mechanism Inoperative NUMBER: 19-001-05 GROUP: Steering DATE: January 26, 2005 SUBJECT: Steering Wheel Tilt Mechanism Inoperative OVERVIEW: This bulletin involves placing a mastic patch over the eyelet of the steering wheel tilt mechanism linkage. MODELS: 2004 - 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan/Voyager 2005 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to Left Hand Drive vehicles only. SYMPTOM/CONDITION: The vehicle operator may experience the steering wheel tilt mechanism is inoperative. DIAGNOSIS: 1. Pull on the tilt release lever to tilt the steering wheel then try and raise or lower the wheel depending on the steering wheel position. 2. If the steering wheel cannot be moved: a. CS vehicles, proceed to CS Repair Procedure: Step # 1. b. RS/RG vehicles, proceed to RS/RG Repair Procedure Step # 1. PARTS REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-001-05 > Jan > 05 > Steering - Steering Wheel Tilt Mechanism Inoperative > Page 6878 Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. RS/RS Procedure 1. Disconnect and isolate the negative (ground) cable from the battery. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. 2. Remove the "Over Steering Column Bezel" by lifting it straight up with a firm pull (not shown). 3. Remove the upper shroud mounting screws. Using your hands on each side of the column, gently press inward at the seams between the two shrouds at points of contact to disengage the inner locking tabs, then remove the upper shroud. If the vehicle is equipped with traction control, the lower shroud will need to be removed once the upper shroud is unfastened in order to disconnect the traction control wiring connector and remove the upper shroud with the traction control switch intact (Fig. 1). 4. If equipped with adjustable pedals, disconnect the wiring connector for the switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-001-05 > Jan > 05 > Steering - Steering Wheel Tilt Mechanism Inoperative > Page 6879 5. Remove the lower shroud mounting screw, then remove the lower shroud (Fig. 2). 6. If equipped with traction control, disconnect the wiring connector from the column wiring harness. Remove the upper shroud with the traction control switch. 7. Remove the screws fastening the fixed shroud in place. Remove the fixed shroud (Fig. 3). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-001-05 > Jan > 05 > Steering - Steering Wheel Tilt Mechanism Inoperative > Page 6880 8. Using locking pliers rotate the tube of the Rotary Tilt Mechanism (RTA) clockwise looking from the steering wheel providing maximum slack in the cable, be careful not to damage the tube (Fig. 4). NOTE: Continue holding the RTA in this position through Step 10. 9. With the other hand place the ball of the cable into the eyelet of the tilt release lever linkage. Push the ball down into the opening until it locks into place (Fig. 5). 10. Rotate the tube counter-clock wise, then release the pliers holding the tube of the RTA. 11. Wipe any excessive grease from the top of the linkage between the hole and the ball. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-001-05 > Jan > 05 > Steering - Steering Wheel Tilt Mechanism Inoperative > Page 6881 12. Center and apply mastic patch (3/4" x 1") about 1-3 mm (0.04- 0.12 in.) from the rivet on linkage, over the hole and around the forward most part of the linkage (Fig. 6). 13. Firmly press down on the mastic patch and hold for 5 seconds. 14. Firmly press the mastic onto the forward edge of the linkage and hold for 5 seconds, then go around edges of the mastic making sure they are secured to the linkage. 15. Install the fixed shroud. Install the screws fastening the fixed shroud in place and tighten the screws to 3 N.m (23 in. lbs.) torque (Fig. 3). 16. If equipped with traction control, position the upper shroud above the column and route the switch wiring down around the column. Connect the wiring connector from the column wiring harness to the traction control switch wiring (attached to upper shroud). 17. Position the lower shroud on the column. Install the lower shroud mounting screw. Tighten the screw to 2 N.m (17 in.lbs.) torque (Fig. 2) 18. If equipped with adjustable pedals, connect the wiring connector for the switch to the column wiring harness. 19. Position the upper shroud on top of the lower shroud and snap it into place. Install the upper shroud mounting screws. Tighten the screws to 2 N.m (17 in.lbs.) torque (Fig. 1). 20. Inspect shroud mating surfaces for excessive gaps and correct as necessary. 21. Install the "Over Steering Column Bezel" by positioning it over the retaining slots and firmly snapping it into place. 22. Connect the battery negative (ground) cable to battery post following special Diagnosis And Testing procedure. Refer to the service information available in TechCONNECT. Reference: Service Info, 8 - Electrical/Restraints - Diagnosis And Testing. WARNING: Failure to connect the battery properly could result in personal injury or death. 23. Reset the clock to the proper time. 24. Verify the vehicle and system operation. 25. Close the hood. CS Repair Procedure 1. Disconnect and isolate the negative (ground) cable from the battery. WARNING: Wait two minutes for the airbag system reserve capacitor to discharge before beginning any airbag system or component service. Failure to do so may result in accidental airbag deployment, personal injury or death. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-001-05 > Jan > 05 > Steering - Steering Wheel Tilt Mechanism Inoperative > Page 6882 2. Remove the steering column opening cover retaining screws and unsnap the cover from instrument panel (Fig. 7). 3. Remove four knee blocker airbag retaining bolts from airbag (Fig. 8). 4. Pull down knee blocker airbag and disconnect the one electrical connector (Fig. 8). 5. Remove knee blocker airbag from vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-001-05 > Jan > 05 > Steering - Steering Wheel Tilt Mechanism Inoperative > Page 6883 6. Remove three screws fastening lower shroud to upper shroud and column (Fig. 9). 7. Remove the four nuts fastening column to dash (Fig. 10). 8. Carefully lower the steering column resting the steering wheel on the seat. 9. Using your hands, gently press inward at the seams between the shrouds at the points where the inner locking tabs exist, unlocking the tabs (Fig. 9). 10. Remove the upper, then lower shroud. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-001-05 > Jan > 05 > Steering - Steering Wheel Tilt Mechanism Inoperative > Page 6884 11. Using locking pliers rotate the tube of the Rotary Tilt Mechanism (RTA) clockwise looking from the steering wheel providing maximum slack in the cable, be careful not to damage tube (Fig. 4). NOTE: Continue holding the RTA in this position through Step 13. 12. With the other hand place the ball of the cable into the eyelet of the tilt release lever linkage. Push the ball down into the opening until it locks into place (Fig. 5). 13. Rotate the tube counter-clockwise, then release the pliers holding the tube of the RTA. 14. Wipe any excessive grease from the top of the linkage between the hole and the ball. 15. Center and apply a mastic patch (3/4" x 1") about 1-3 mm from the rivet on linkage, over the hole and around the forward most part of the linkage (Fig. 6). 16. Firmly press down on the mastic patch and hold for 5 seconds. 17. Firmly press the mastic onto the forward edge of the linkage and hold for 5 seconds, then go around the edges of the mastic making sure they are secured to the linkage. 18. Install the upper and lower shroud. 19. Snap the shrouds together at the locking tab locations on both sides. NOTE: The screws securing the shrouds will be installed later as part of Step # 22. 20. Raise the steering column into place and loosely install the four nuts. Tighten the four nuts to 12 N.m (105 in.lbs.) torque. 21. Install the center mounting screw securing the lower shroud to the column. Tighten the screw to 2 N.m (18 in.lbs.) torque. 22. Install the two outer mounting screws securing the lower shroud to the upper shroud. Tighten the screws to 2 N.m (18 in. lbs.) torque. 23. Inspect the shroud mating surfaces for excessive gaps and adjust as necessary. 24. Place the knee blocker airbag into position in the instrument panel opening. 25. Connect the electrical connector (Fig. 8). 26. Install the four knee blocker airbag retaining bolts and secure the knee blocker airbag in place (Fig. 8). 27. Position the steering column opening cover over the retaining slots and firmly snap into place. Install the two retaining screws (Fig. 7). 28. Connect the battery negative (ground) cable to battery post following special Diagnosis And Testing procedure. Refer to the service information available in TechCONNECT. Reference: Service Info, 8 - Electrical/Restraints - Diagnosis And Testing. WARNING: Failure to connect the battery properly could result in personal injury or death. 29. Reset the clock to the proper time. 30. Verify the vehicle and system operation. 31. Close the hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest for Steering Gear: > 19-011-04 > Dec > 04 > Steering - Moaning Noise on Low Speed Turns Steering Gear: Customer Interest Steering - Moaning Noise on Low Speed Turns NUMBER: 19-011-04 GROUP: Steering DATE: December 7, 2004 SUBJECT: Moan/Fog Horn Like Sound While Turning During Slow Speed Or Parking Lot Maneuvers. OVERVIEW: This bulletin involves installing a finned power steering fluid cooler package and if necessary, a steering gear. MODELS: 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles built on or before September 13, 2004 (MDH 0913XX). SYMPTOM/CONDITION: The vehicle operator may describe a moan/fog horn like sound while turning during slow speed or parking lot maneuvers. The sound may occur throughout the steering range, off center, but not at the wheel stops. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: CAUTION: Throughout the following procedure, special care should be taken to prevent introducing contamination into the power steering system. 1. Open the hood. 2. Remove the cap from the power steering fluid reservoir. 3. Using a siphon pump/suction gun, remove as much power steering fluid as possible from the power steering fluid reservoir. 4. Remove and save the constant tension spring clamp securing the power steering return line hose to the power steering fluid reservoir. 5. Remove the rubber hose portion of the power steering return line from the power steering fluid reservoir fitting. 6. Drain the power steering fluid reservoir into an appropriate container. NOTE: This fluid should not be reused to avoid introducing contamination from the container. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest for Steering Gear: > 19-011-04 > Dec > 04 > Steering - Moaning Noise on Low Speed Turns > Page 6893 7. Raise the vehicle on an appropriate hoist. 8. Remove the fuel vapor canister. 9. Locate the bracket connecting the power steering return line cooler loop to the cradle reinforcement plate (Fig. 1). 10. Remove the fasteners connecting the cooler line to the reinforcement plate. Save the fasteners for use in Step # 17. 11. Locate the bracket connecting the power steering pressure line to the cradle reinforcement plate (Fig. 1). 12. Remove the fastener connecting the bracket to the reinforcement plate. Save the fastener for use in Step # 18. 13. Remove and discard the J/U nut clip on the bracket. 14. Locate and unscrew the tube nut connecting the power steering return line to the steering gear pinion housing. NOTE: The tube nut will remain loosely assembled to the power steering return line. 15. Drain the remaining fluid into an appropriate container and discard the loop cooler line that was removed from the vehicle. NOTE: This fluid should not be reused to avoid introducing contamination from the container. 16. Install the new power steering return line, p/n 04743473AE. Attach the power steering return line tube nut to the steering gear pinion housing and tighten to 27.1 - 35.0 N.m (240 - 310 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest for Steering Gear: > 19-011-04 > Dec > 04 > Steering - Moaning Noise on Low Speed Turns > Page 6894 17. Reuse the fastener removed in Step # 10. Install the fastener into the left weld nut on the cooler fin pack bracket and the left hole in the cradle reinforcement plate. Tighten the fastener to 9-11.3 Nm (80-100 in. lbs.) (Fig. 2). 18. Line up the pressure line bracket and the right weld nut in the cooler fin pack bracket. Reuse the fastener removed in Step # 12. Install the fastener through the right hole in the cradle reinforcement plate, the fin pack bracket and the pressure line bracket. Tighten the fastener to 9 11.3 N.m (80-100 in. lbs.) (Fig. 2). 19. Install the fuel vapor canister. 20. Lower the vehicle. 21. Install the constant tension spring clamp removed in Step # 4 onto the rubber hose on the power steering return line. Slide the clamp so that it is 3 inches from the end of the rubber hose. 22. Push the end of the rubber hose portion of the power steering return line onto the power steering fluid reservoir suction port. Secure the hose by sliding the constant spring tension clamp installed on the hose in the last step, to within 6 mm (0.25 in.) of the end of the rubber hose. Be sure the hose clamp is installed past the bead on fluid reservoir fitting. 23. Fill the power steering system. Refer to Steering/Pump - Standard Procedure at the end of this bulletin. 24. Test drive the vehicle in the parking lot. Determine if the sound, as describe in the Symptom/Condition section of this bulletin, is still present. 25. If the sound is no longer present. The repair is complete. If the sound is still present, replace the steering gear using the appropriate part number according to the Parts Required table above. Refer to the service information available in TechCONNECT. Refer to 19 - Steering/Gear Removal and Installation. 26. Fill the power steering system. Refer to Steering/Pump - Standard Procedure below. STEERING/PUMP - STANDARD PROCEDURE WARNING: FLUID LEVEL SHOULD BE CHECKED AND ADJUSTED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING ENGINE COMPONENTS. CAUTION: Use only Mopar(R) ATF+4 Automatic Transmission Fluid (MS-9602) in power steering system. Use of other Mopar(R) power steering fluids (M55931 and M59933) should be avoided to ensure peak performance of the power steering system under all operating conditions. Do not overfill. Read the fluid level through the side of the power steering fluid reservoir. The fluid level should be within "FILL RANGE" when the fluid is at a temperature of approximately 21 °C to 27°C (70°F to 80°F). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Customer Interest for Steering Gear: > 19-011-04 > Dec > 04 > Steering - Moaning Noise on Low Speed Turns > Page 6895 1. Wipe the filler cap and area clean, then remove the cap. 2. Fill the fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 3. Start the engine and let run for a few seconds, then turn the engine off. 4. Add fluid if necessary. Repeat the above steps until the fluid level remains constant after running the engine. 5. Raise the front wheels off the ground. 6. Start the engine. 7. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 8. Add fluid if necessary. 9. Lower the vehicle, then turn the steering wheel slowly from lock-to-lock. 10. Stop the engine. Check the fluid level and refill as required. 11. If the fluid is extremely foamy, allow the vehicle to stabilize a few minutes, then repeat the above procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-011-04 > Dec > 04 > Steering - Moaning Noise on Low Speed Turns Steering Gear: All Technical Service Bulletins Steering - Moaning Noise on Low Speed Turns NUMBER: 19-011-04 GROUP: Steering DATE: December 7, 2004 SUBJECT: Moan/Fog Horn Like Sound While Turning During Slow Speed Or Parking Lot Maneuvers. OVERVIEW: This bulletin involves installing a finned power steering fluid cooler package and if necessary, a steering gear. MODELS: 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to vehicles built on or before September 13, 2004 (MDH 0913XX). SYMPTOM/CONDITION: The vehicle operator may describe a moan/fog horn like sound while turning during slow speed or parking lot maneuvers. The sound may occur throughout the steering range, off center, but not at the wheel stops. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: CAUTION: Throughout the following procedure, special care should be taken to prevent introducing contamination into the power steering system. 1. Open the hood. 2. Remove the cap from the power steering fluid reservoir. 3. Using a siphon pump/suction gun, remove as much power steering fluid as possible from the power steering fluid reservoir. 4. Remove and save the constant tension spring clamp securing the power steering return line hose to the power steering fluid reservoir. 5. Remove the rubber hose portion of the power steering return line from the power steering fluid reservoir fitting. 6. Drain the power steering fluid reservoir into an appropriate container. NOTE: This fluid should not be reused to avoid introducing contamination from the container. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-011-04 > Dec > 04 > Steering - Moaning Noise on Low Speed Turns > Page 6901 7. Raise the vehicle on an appropriate hoist. 8. Remove the fuel vapor canister. 9. Locate the bracket connecting the power steering return line cooler loop to the cradle reinforcement plate (Fig. 1). 10. Remove the fasteners connecting the cooler line to the reinforcement plate. Save the fasteners for use in Step # 17. 11. Locate the bracket connecting the power steering pressure line to the cradle reinforcement plate (Fig. 1). 12. Remove the fastener connecting the bracket to the reinforcement plate. Save the fastener for use in Step # 18. 13. Remove and discard the J/U nut clip on the bracket. 14. Locate and unscrew the tube nut connecting the power steering return line to the steering gear pinion housing. NOTE: The tube nut will remain loosely assembled to the power steering return line. 15. Drain the remaining fluid into an appropriate container and discard the loop cooler line that was removed from the vehicle. NOTE: This fluid should not be reused to avoid introducing contamination from the container. 16. Install the new power steering return line, p/n 04743473AE. Attach the power steering return line tube nut to the steering gear pinion housing and tighten to 27.1 - 35.0 N.m (240 - 310 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-011-04 > Dec > 04 > Steering - Moaning Noise on Low Speed Turns > Page 6902 17. Reuse the fastener removed in Step # 10. Install the fastener into the left weld nut on the cooler fin pack bracket and the left hole in the cradle reinforcement plate. Tighten the fastener to 9-11.3 Nm (80-100 in. lbs.) (Fig. 2). 18. Line up the pressure line bracket and the right weld nut in the cooler fin pack bracket. Reuse the fastener removed in Step # 12. Install the fastener through the right hole in the cradle reinforcement plate, the fin pack bracket and the pressure line bracket. Tighten the fastener to 9 11.3 N.m (80-100 in. lbs.) (Fig. 2). 19. Install the fuel vapor canister. 20. Lower the vehicle. 21. Install the constant tension spring clamp removed in Step # 4 onto the rubber hose on the power steering return line. Slide the clamp so that it is 3 inches from the end of the rubber hose. 22. Push the end of the rubber hose portion of the power steering return line onto the power steering fluid reservoir suction port. Secure the hose by sliding the constant spring tension clamp installed on the hose in the last step, to within 6 mm (0.25 in.) of the end of the rubber hose. Be sure the hose clamp is installed past the bead on fluid reservoir fitting. 23. Fill the power steering system. Refer to Steering/Pump - Standard Procedure at the end of this bulletin. 24. Test drive the vehicle in the parking lot. Determine if the sound, as describe in the Symptom/Condition section of this bulletin, is still present. 25. If the sound is no longer present. The repair is complete. If the sound is still present, replace the steering gear using the appropriate part number according to the Parts Required table above. Refer to the service information available in TechCONNECT. Refer to 19 - Steering/Gear Removal and Installation. 26. Fill the power steering system. Refer to Steering/Pump - Standard Procedure below. STEERING/PUMP - STANDARD PROCEDURE WARNING: FLUID LEVEL SHOULD BE CHECKED AND ADJUSTED WITH ENGINE OFF TO PREVENT INJURY FROM MOVING ENGINE COMPONENTS. CAUTION: Use only Mopar(R) ATF+4 Automatic Transmission Fluid (MS-9602) in power steering system. Use of other Mopar(R) power steering fluids (M55931 and M59933) should be avoided to ensure peak performance of the power steering system under all operating conditions. Do not overfill. Read the fluid level through the side of the power steering fluid reservoir. The fluid level should be within "FILL RANGE" when the fluid is at a temperature of approximately 21 °C to 27°C (70°F to 80°F). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-011-04 > Dec > 04 > Steering - Moaning Noise on Low Speed Turns > Page 6903 1. Wipe the filler cap and area clean, then remove the cap. 2. Fill the fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes. 3. Start the engine and let run for a few seconds, then turn the engine off. 4. Add fluid if necessary. Repeat the above steps until the fluid level remains constant after running the engine. 5. Raise the front wheels off the ground. 6. Start the engine. 7. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 8. Add fluid if necessary. 9. Lower the vehicle, then turn the steering wheel slowly from lock-to-lock. 10. Stop the engine. Check the fluid level and refill as required. 11. If the fluid is extremely foamy, allow the vehicle to stabilize a few minutes, then repeat the above procedure. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 6904 Steering Gear: Service Precautions WARNINGS AND CAUTIONS WARNING: POWER STEERING FLUID, ENGINE PARTS AND EXHAUST SYSTEM MAY BE EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. DO NOT START ENGINE WITH ANY LOOSE OR DISCONNECTED HOSES. DO NOT ALLOW HOSES TO TOUCH HOT EXHAUST MANIFOLD OR CATALYST. WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: When the system is open, cap all open ends of the hoses, power steering pump fittings or power steering gear ports to prevent entry of foreign material into the components. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical Service Bulletins > Page 6905 Steering Gear: Description and Operation GEAR DESCRIPTION This vehicle is equipped with a rack and pinion power steering gear (Fig. 1). It is mounted to the underside of the front suspension cradle/crossmember. The steering column is attached to the gear through the use of an intermediate shaft and couplers. The outer ends of the power steering gear's outer tie rods connect to the steering knuckles. NOTE: The power steering gear should NOT be serviced or adjusted unless Daimler/Chrysler Corporation authorizes. If a malfunction or oil leak occurs, the complete steering gear should be replaced. Only the outer tie rods may be replaced separately from the rest of the gear. OPERATION Turning of the steering wheel is converted into linear (side-to-side) travel through the meshing of the helical pinion teeth with the rack teeth in the steering gear. This travel pushes and pulls the tie rods to change the direction of the vehicle's front wheels. Power assist steering provided by the power steering pump is controlled by an open center, rotary type control valve which directs oil from the pump to either side of the integral rack piston upon demand. Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle. As required steering effort increases, as in a turn, the torsion bar twists, causing relative rotary motion between the rotary valve body and the valve spool. This movement directs oil behind the integral rack piston which, in turn, builds hydraulic pressure and assists in the turning effort. Manual steering control of the vehicle can be maintained if power steering assist is lost. However, under this condition, steering effort is significantly increased. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > With LHD Gear Steering Gear: Service and Repair With LHD Gear LHD GEAR REMOVAL 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much fluid as possible from the power steering fluid reservoir. Use care not to damage the filter mesh below the fluid surface. CAUTION: Locking the steering column in the straight-ahead position will prevent the clockspring from being accidentally over-extended when the steering column is disconnected from the intermediate steering coupler. 3. Position the steering wheel in the STRAIGHT AHEAD position. Lock the steering wheel in place using a steering wheel holding tool. 4. With the vehicle on the ground, disconnect the steering column shaft coupler from the steering gear intermediate coupler (Fig. 2). 5. Raise vehicle. 6. Remove front wheel and tire assemblies. 7. Remove front emissions vapor canister. 8. Remove a single hose at power steering cooler and allow fluid to drain. 9. Remove 2 bolts attaching power steering cooler to cradle crossmember reinforcement (Fig. 3). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > With LHD Gear > Page 6908 10. On both sides of vehicle, remove nut attaching outer tie rod end to steering knuckle (Fig. 4). Remove nut by holding tie rod end stud with a socket while loosening and removing nut with wrench. 11. Remove bolts fastening leak detection pump to cradle crossmember reinforcement. 12. Remove both outer tie rods from steering knuckles, using Puller, Special Tool C-3894-A (Fig. 5). 13. Remove the lower control arm rear bushing retainer bolts located on each side of each lower control arm rear bushing. NOTE: The bolts fastening the cradle crossmember reinforcement are of two different thread sizes. Note the location of the various sizes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > With LHD Gear > Page 6909 14. Remove the bolts attaching the cradle crossmember reinforcement to the front suspension cradle crossmember (Fig. 6). Remove the 2 bolts fastening the reinforcement and rear of cradle crossmember to the body of the vehicle. Remove lower rear bushings, then the reinforcement. 15. If the vehicle is equipped with All-Wheel- remove the power transfer unit as necessary Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > With LHD Gear > Page 6910 16. Remove tube nuts and power steering pressure and return hoses from the power steering gear (Fig. 7). 17. Remove the 3 bolts and nuts mounting the steering gear to the front suspension cradle (Fig. 8). NOTE: The next step must be done to allow the removal of the steering gear from the front suspension cradle. The steering gear can not be removed from the vehicle with the intermediate coupler attached to the steering gear. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > With LHD Gear > Page 6911 18. Lower steering gear from suspension cradle enough to allow access to the intermediate coupler roll pin (Fig. 9). Install Remover/Installer Special Tool 6831A through the center of the roll pin, securing with the knurled nut (Fig. 9). Hold threaded rod stationary while turning nut, this will pull the roll pin out of the intermediate coupler. 19. Separate the coupler from the shaft of the steering gear. 20. Remove the power steering gear from the vehicle. INSTALLATION 1. Install the power steering gear up in the front suspension cradle, leaving room to install intermediate coupler. 2. Start the roll pin into the intermediate coupler before installing coupler on steering gear shaft. Start roll pin into coupler, using a hammer and tapping it into the coupler. Then install the intermediate coupler on the shaft of the steering gear. 3. Install Remover/Installer Special Tool 6831A through the center of the roll pin, securing it with the knurled nut (Fig. 12). Hold threaded rod stationary while turning nut, this will pull the roll pin into the intermediate coupler CAUTION: Proper torque on the steering gear to suspension cradle mounting bolts is very important. 4. Install steering gear on the front suspension cradle. Install the 3 steering gear mounting bolts and nuts (Fig. 8). Tighten the 3 mounting bolts to the following torque values: 14 mm bolt - 183 Nm (135 ft. lbs.) torque - 12 mm bolt - 95 Nm (70 ft. lbs.) torque 5. Attach the power steering fluid pressure and return hoses to the correct ports on the power steering gear (Fig. 7). Tighten the hose tube nuts at the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > With LHD Gear > Page 6912 gear to a torque of 31 Nm (275 inch lbs.). 6. If the vehicle is equipped with All-Wheel-Drive, install the power transfer unit as necessary. CAUTION: Proper torque on the cradle reinforcement to suspension cradle mounting bolts is very important. 7. Install the reinforcement on the front suspension cradle crossmember and install the bolts attaching the reinforcement to the cradle crossmember (Fig. 6). Tighten the M-14 size bolts to a torque of 153 Nm (113 ft. lbs.). Tighten the M-12 size bolts to a torque of 106 Nm (78 ft. lbs.). 8. Install the lower control arm rear bushing retainer bolts (M-10 size) through reinforcement on each side of each lower control arm rear bushing. Tighten bolts to a torque of 61 Nm (45 ft. lbs.). 9. Install the two bolts and bushings attaching the reinforcement and rear of cradle crossmember to body of vehicle (Fig. 6). Tighten bolts to a torque of 163 Nm (120 ft. lbs.). 10. Install outer tie rod end into steering knuckle. Start outer tie rod to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary using a socket (Fig. 4), tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and socket (Fig. 13), tighten the tie rod end attaching nut to a torque of 75 Nm (55 ft. lbs.). 11. Install leak detection pump on cradle crossmember reinforcement. 12. Install the power steering fluid cooler on the cradle crossmember reinforcement (Fig. 3). Install the mounting bolts and tighten to 11 Nm (100 inch lbs.). When installing mounting bolts, include pressure hose routing clamp. 13. Reconnect previously disconnected hose at power steering cooler and install clamp. 14. Install the front tire and wheel assemblies on vehicle. Install the wheel lug nuts and torque to 135 Nm (100 ft. lbs.). 15. Install front emissions vapor canister. 16. Lower the vehicle to a level where the interior of vehicle is accessible. 17. With the wheels pointed approximately STRAIGHT-AHEAD, align the intermediate shaft with the steering column coupler. Assemble the steering column shaft coupler onto the steering gear intermediate coupler (Fig. 2). Install steering column coupler to intermediate shaft retaining pinch bolt. Tighten the pinch bolt nut to a torque of 28 Nm (250 inch lbs.). 18. Remove the steering wheel holding tool. 19. Fill and bleed the power steering system using the Power Steering Pump Initial Operation Procedure. 20. Inspect system for leaks. 21. Adjust front toe. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > With LHD Gear > Page 6913 Steering Gear: Service and Repair With RHD Gear RHD GEAR REMOVAL 1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much fluid as possible from the power steering fluid reservoir. CAUTION: Locking the steering column in the straight-ahead position will prevent the clockspring from being accidentally over-extended when the steering column is disconnected from the intermediate steering coupler. 3. Position the steering wheel in the STRAIGHT AHEAD position. Lock the steering wheel in place using a steering wheel holding tool. 4. With the ignition key in the locked position turn the steering wheel to the left until the steering wheel is in the locked position. 5. With the vehicle on the ground, disconnect the steering column shaft coupler from the steering gear intermediate coupler (Fig. 2). 6. Raise vehicle. 7. Remove front wheel and tire assemblies. 8. If power steering cooler equipped, remove a hose at power steering cooler and allow fluid to drain. 9. Remove 2 bolts attaching power steering cooler to cradle crossmember reinforcement (Fig. 3). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > With LHD Gear > Page 6914 10. On both sides of vehicle, remove nut attaching outer tie rod end to steering knuckle (Fig. 4). Remove nut by holding tie rod end stud with a socket while loosening and removing nut with wrench. 11. Remove both tie rod ends from steering knuckles using Puller, Special Tool C-3894-A (Fig. 5). 12. Remove the lower control arm rear bushing retainer bolts located on each side of each lower control arm rear bushing. NOTE: The bolts fastening the cradle crossmember reinforcement are of two different thread sizes. Note the location of the various sizes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > With LHD Gear > Page 6915 13. Remove the bolts attaching the cradle crossmember reinforcement to the front suspension cradle crossmember (Fig. 6). Remove the 2 bolts fastening the reinforcement and rear of cradle crossmember to the body of the vehicle. Remove the reinforcement. 14. If the vehicle is equipped with All-Wheel - remove the power transfer unit. 15. Remove the power steering fluid pressure and return hoses from the power steering gear (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > With LHD Gear > Page 6916 16. Remove the routing clamp bolt securing the power steering fluid hoses to the rear of the cradle crossmember (Fig. 11). Allow the hoses to hang down out of the way. 17. Remove the heat shield from the steering gear (Fig. 10). 18. Remove the 2 bolts and nuts mounting the steering gear to the front suspension cradle. NOTE: The next step must be done to allow the removal of the steering gear from the front suspension cradle. The steering gear cannot be removed from the vehicle with the intermediate coupler attached to the steering gear. 19. Lower steering gear from suspension cradle enough to allow access to the intermediate coupler roll pin (Fig. 9). Install Remover/Installer, Special Tool 6831A, through the center of the roll pin, securing with the knurled nut (Fig. 9). Hold threaded rod stationary while turning nut, this will pull the roll pin out of the intermediate coupler. 20. Separate the coupler from the steering gear shaft. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > With LHD Gear > Page 6917 21. Remove the power steering gear from the vehicle. INSTALLATION - RHD GEAR 1. Install the steering gear up in the front suspension cradle crossmember, leaving room to install intermediate coupler. 2. Start the roll pin into the intermediate coupler before installing coupler on steering gear shaft. Start roll pin into coupler, using a hammer and tapping it into the coupler. Then install the intermediate coupler on the shaft of the steering gear. 3. Install Remover/Installer Special Tool 6831A through the center of the roll pin, securing it with the knurled nut (Fig. 12). Hold threaded rod stationary while turning nut. This will pull the roll pin into the intermediate coupler. 4. Install power steering gear on the front suspension cradle. Install the 2 steering gear mounting bolts and nuts. Tighten the M-14 size steering gear to suspension cradle mounting bolt to a torque of 183 Nm (135 ft. lbs.). Tighten the M-12 size steering gear to suspension cradle mounting bolt to a torque of 95 Nm (70 ft. lbs.). CAUTION: Proper torque on the steering gear to suspension cradle mounting bolts is very important. 5. Install the heat shield on the steering gear (Fig. 10). 6. Attach the power steering fluid pressure and return hoses to the proper fittings on the steering gear (Fig. 10). Do not fully tighten the fittings at this time. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > With LHD Gear > Page 6918 7. Install the routing clamp with the bolt securing the power steering fluid hoses to the rear of the cradle crossmember (Fig. 11). 8. Using a crowfoot wrench on a torque wrench, tighten the power steering fluid hose tube nuts at the gear to a torque of 31 Nm (275 inch lbs.). 9. Install tie rod end into steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary using a socket (Fig. 4), tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and socket (Fig. 13), tighten the tie rod end attaching nut to a torque of 75 Nm (55 ft. lbs.). 10. If the vehicle is equipped with All-Wheel - install the power transfer unit. CAUTION: Proper torque on the cradle reinforcement to suspension cradle mounting bolts is very important. 11. Install the reinforcement on the front suspension cradle crossmember and install the bolts attaching the reinforcement to the cradle crossmember (Fig. 6). Tighten the M-14 size bolts to a torque of 163 Nm (120 ft. lbs.). Tighten the M-12 size bolts to a torque of 108 Nm (80 ft. lbs.). 12. Install the lower control arm rear bushing retainer bolts through reinforcement on each side of each lower control arm rear bushing. Tighten bolts to a torque of 61 Nm (45 ft. lbs.). 13. Install the two bolts and bushings attaching the reinforcement and rear of cradle crossmember to body of vehicle (Fig. 6). Tighten bolts to a torque Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > With LHD Gear > Page 6919 of 163 Nm (120 ft. lbs.). 14. If power steering cooler equipped, install the previously disconnected power steering cooler hose on the cooler. Install the clamp. 15. If power steering cooler equipped, install the power steering fluid cooler on the cradle crossmember reinforcement (Fig. 3). Install the mounting bolts and tighten to 11 Nm (100 inch lbs.). 16. Install the front tire and wheel assemblies on vehicle. Install the wheel mounting lug nuts and tighten to a torque to 135 Nm (100 ft. lbs.). 17. Lower the vehicle to a level were the interior of vehicle is accessible (keeping tires off the ground). 18. With the wheels pointed approximately STRAIGHT-AHEAD, align the intermediate shaft with the steering column coupler. Assemble the steering column shaft coupler onto the steering gear intermediate coupler (Fig. 2). Install steering column coupler to intermediate shaft retaining pinch bolt. Tighten the pinch bolt nut to a torque of 28 Nm (250 inch lbs.). 19. Remove the steering wheel holding tool. 20. Perform the POWER STEERING PUMP INITIAL OPERATION procedure to properly fill and bleed the power steering system. 21. Inspect for leaks. 22. Adjust front wheel toe. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Page 6920 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 19-007-05A > Sep > 05 > Interior - Rattle From Steering Wheel Steering Wheel: Customer Interest Interior - Rattle From Steering Wheel NUMBER: 19-007-05 REV. A GROUP: Steering DATE: September 30, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-05, DATED AUGUST 12, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL MODEL YEAR AND A REVISED APPLICABILITY DATE SUBJECT: Rattle Sound From Steering Wheel Area OVERVIEW: This bulletin involves installing an empty wiring track. MODELS: 2005 - **2006** (RS) Town & Country/Caravan 2005 - **2006** (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to vehicles WITHOUT Speed Control (sales code NHM) built on or before **September 26, 2005 (MDH0926XX)**. SYMPTOM/CONDITION: Rattle Sound From Steering Wheel Area DIAGNOSIS: If the Symptom/Condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: WARNING: Wait two minutes after disconnecting the battery for the system reserve capacitor to discharge before beginning any airbag component service. Personal injury or death may result. 1. Remove the driver's airbag. Refer to the detailed removal procedures available in TechCONNECT, under: Service Info, 8 - Electrical, Restraints, Driver Airbag, Removal. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Customer Interest for Steering Wheel: > 19-007-05A > Sep > 05 > Interior - Rattle From Steering Wheel > Page 6929 2. Install the wire track, p/n 05189397AA, on the back of the driver's air bag, on the four studs (Fig. 1). 3. Install the driver's air bag in the vehicle. Refer to the detailed installation procedures available in TechCONNECT, under: Service Info, 8 - Electrical, Restraints, Driver Airbag, Installation. WARNING: Do not connect the battery negative cable! Refer to the detailed service information available in TechCONNECT, under: Service Info, 8 - Electrical/Restraints - Diagnosis And Testing - Airbag System. Personal injury or death may result if the system test is not performed first. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 19-007-05A > Sep > 05 > Interior - Rattle From Steering Wheel Steering Wheel: All Technical Service Bulletins Interior - Rattle From Steering Wheel NUMBER: 19-007-05 REV. A GROUP: Steering DATE: September 30, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-05, DATED AUGUST 12, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL MODEL YEAR AND A REVISED APPLICABILITY DATE SUBJECT: Rattle Sound From Steering Wheel Area OVERVIEW: This bulletin involves installing an empty wiring track. MODELS: 2005 - **2006** (RS) Town & Country/Caravan 2005 - **2006** (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to vehicles WITHOUT Speed Control (sales code NHM) built on or before **September 26, 2005 (MDH0926XX)**. SYMPTOM/CONDITION: Rattle Sound From Steering Wheel Area DIAGNOSIS: If the Symptom/Condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: WARNING: Wait two minutes after disconnecting the battery for the system reserve capacitor to discharge before beginning any airbag component service. Personal injury or death may result. 1. Remove the driver's airbag. Refer to the detailed removal procedures available in TechCONNECT, under: Service Info, 8 - Electrical, Restraints, Driver Airbag, Removal. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 19-007-05A > Sep > 05 > Interior - Rattle From Steering Wheel > Page 6935 2. Install the wire track, p/n 05189397AA, on the back of the driver's air bag, on the four studs (Fig. 1). 3. Install the driver's air bag in the vehicle. Refer to the detailed installation procedures available in TechCONNECT, under: Service Info, 8 - Electrical, Restraints, Driver Airbag, Installation. WARNING: Do not connect the battery negative cable! Refer to the detailed service information available in TechCONNECT, under: Service Info, 8 - Electrical/Restraints - Diagnosis And Testing - Airbag System. Personal injury or death may result if the system test is not performed first. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 6936 Steering Wheel: Service and Repair STEERING WHEEL REMOVAL 1. Disconnect and isolate the negative (ground) cable from the battery. Wait at least two minutes for the airbag system reserve capacitor to discharge before beginning any steering column, instrument panel, or airbag system/component service. WARNING: WHEN AN UNDEPLOYED AIRBAG IS TO BE REMOVED FROM THE VEHICLE, FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. ALLOW THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE BEGINNING ANY AIRBAG SYSTEM OR COMPONENT SERVICE. PERSONAL INJURY MAY RESULT IF THIS PROCEDURE IS NOT FOLLOWED. 2. Remove the driver airbag mounting screws (Fig. 40). 3. Lift the airbag from its mount and disconnect two airbag squib, speed control and horn connectors (Fig. 41). Remove driver airbag. Properly store the driver airbag out of the way. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 6937 4. Remove the steering wheel retaining bolt (Fig. 42). 5. Remove damper (Fig. 42). 6. If equipped, disconnect the remote audio control switch wiring from the clockspring (Fig. 42). CAUTION: Do not bump or hammer on steering column or steering column shaft when removing steering wheel from steering column shaft. CAUTION: When installing steering wheel puller bolts in steering wheel, do not thread bolt into steering wheel more than a half inch. If the bolts are threaded into the steering wheel more than a half inch they will contact and damage the clockspring. 7. While holding the steering wheel firmly in the straight-ahead position, remove the steering wheel from steering column shaft using a steering wheel puller (Fig. 43). 8. Remove the puller from the steering wheel. 9. Remove the remote radio switches if needed. INSTALLATION 1. If needed, install the remote radio switches. CAUTION: Do not force steering wheel onto steering column shaft by driving it on. Pull steering wheel down onto shaft using only the steering wheel retaining nut. 2. Feed and route wiring from clockspring through upper access hole in steering wheel. 3. Align master serrations in steering wheel with omitted spline on steering column shaft (at 12 o'clock position). Slide the steering wheel onto the steering column shaft by hand (Fig. 42). Use care not to pinch any wiring. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical Service Bulletins > Page 6938 NOTE: Before installing the damper on the steering wheel, inspect the damper to ensure the rubber isolator on the damper is not deteriorated or damaged. If the damper is installed with a damaged isolator, a buzz, squeak or rattle condition may develop. 4. Install the damper on the steering wheel (Fig. 42). 5. Install the steering wheel retaining bolt. Tighten the steering wheel retaining bolt to 61 Nm (45 ft. lbs.) torque. 6. If the steering wheel is equipped with remote audio controls, connect the wiring connector to the clockspring (Fig. 42). 7. Connect the airbag squib wiring connectors to the airbag and the horn and speed control switch connector to the clockspring (Fig. 41). 8. Install the driver airbag in the steering wheel (Fig. 40). Install and tighten the airbag attaching screws to 10 Nm (90 inch lbs.) torque. 9. Connect the battery negative (ground) cable to battery post following special Diagnosis And Testing procedure. 10. Check operation of all steering wheel mounted components. 11. Road test vehicle to ensure proper operation of steering. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod Tie Rod End: Service and Repair Outer Tie Rod OUTER TIE ROD REMOVAL 1. Loosen inner tie rod to outer tie rod jam nut (Fig. 14). 2. Remove nut attaching outer tie rod end to steering knuckle (Fig. 15). The nut is to be removed from tie rod end by holding tie rod end stud with an 11/32 socket while loosening and removing nut with a wrench. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod > Page 6944 3. Remove the tie rod end stud from steering knuckle arm, using Remover, Special Tool C-3894-A (Fig. 16). 4. Remove outer tie rod end by un-threading it from the inner tie rod. INSTALLATION NOTE: Before installing the outer tie rod, make sure the jam nut is on inner tie rod (Fig. 14). 1. Install outer tie rod onto inner tie rod. 2. Do not tighten jam nut. 3. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle attaching nut (Fig. 15). Then using a crowfoot and 11/32 socket (Fig. 17), torque tie rod end attaching nut to 75 Nm (55 ft. lbs.). 4. Tighten tie rod jam nut (Fig. 14) to 75 Nm (55 ft. lbs.) torque. CAUTION: During this procedure do not allow the steering gear boot to become twisted. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod > Page 6945 5. Adjust the front toe setting on the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod > Page 6946 Tie Rod End: Service and Repair Outer/InnerTie Rod End REMOVAL NOTE: The following procedures cover both inner and outer tie rod removal. The outer tie rod must be removed before the inner tie rod can be removed. OUTER TIE ROD Raise and support vehicle. 2. Remove front wheel and tire assembly. See: Wheels and Tires 3. Turn wheel to full stop to extend inner tie rod being serviced outward. 4. Loosen inner tie rod to outer tie rod jam nut. 5. Remove nut attaching outer tie rod end to steering knuckle. To do this, hold tie rod end stud stationary with a socket while loosening and removing nut with a wrench. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod > Page 6947 6. Remove tie rod end stud from steering knuckle arm using Remover, Special Tool C-3894-A. 7. Remove outer tie rod end by unthreading it from inner tie rod. Count number of turns required to remove outer tie rod. This will aid during installation. INNER TIE ROD 1. Remove outer tie rod. Refer to above procedure. 2. Remove tie rod jam nut from inner tie rod. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod > Page 6948 1. Bellows 2. Inner Clamp 3. Clamp 3. Remove clamp securing bellows to inner tie rod. 4. Left side only Remove leak detection pump mounting screws, then move pump toward center of vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod > Page 6949 1. Clamp 2. Tranfer Tube Clamp 5. Remove clamp securing bellows to steering gear body). 6. Remove clamp securing bellows to transfer tube. 7. Remove bellows from inner tie rod. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod > Page 6950 1. Travel Restrictor 2. Inner Tie Rod 3. Hex For Removal/Installation 8. Remove travel restrictor from inner tie rod. 9. Install appropriate inner tie rod removal tool. CAUTION: Place an appropriate size wrench on the exposed section of the rack gear while loosening the inner tie rod to resist rotation and prevent damage to the gear mechanism. Do not use a tool that could damage the rack gear. CAUTION: If inner tie rod cannot be removed using specified tools, do not use a hammer or heat to loosen. Damage to steering gear will occur. Replace entire steering gear. 10. While holding rack gear stationary using an appropriate size wrench placed on exposed section of rack gear, unthread and remove inner tie rod . INSTALLATION NOTE:The following procedures cover both inner and outer tie rod installation. The inner tie rod must be installed before the outer tie rod can be installed. INNER TIE ROD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod > Page 6951 1. Restrictor 2. Flat Side Of Teeth 1. Install travel restrictor, flat side of teeth facing out, on inboard end of inner tie rod ball joint. 2. Apply Mopar® Lock & Seal Adhesive or equivalent medium thread locker adhesive to inboard end threads of inner tie rod. CAUTION:Place an appropriate size wrench on the exposed section of the rack gear to resist rotation and prevent damage to the gear mechanism during inner tie rod installation. Do not use a tool that could damage the rack gear. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod > Page 6952 1. Travel Restrictor 2. Inner Tie Rod 3. Hex For Removal/Installation 3. Install inner tie rod onto gear using appropriate inner tie rod installer tool or crows foot wrench. While holding rack gear stationary using an appropriate size wrench placed on exposed section of rack gear tighten inner tie rod to 78 N.m, (58 ft. lbs.). 4. Apply a small amount of Mopar® Lubriplate or equivalent uniformly to groove in inner tie rod shaft where bellows mounts. This allows for toe adjustment without twisting bellows. 5. Place new transfer tube clamp over transfer tube past where bellows will mount. 6. Loosely place new clamp over large end of bellows. 7. Slide new bellows with clamp over end of inner tie rod and onto gear body and transfer tube. 8. Push small end of bellows past groove machined into inner tie rod, then pull it outward until ridge inside bellows engages groove. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod > Page 6953 1. Clamp 2. Tranfer Tube Clamp 9. Install clamp securing bellows to transfer tube. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod > Page 6954 1. Clamp 2. Clamping Pliers 10. Using crimping pliers, crimp bellows clamp at gear body. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod > Page 6955 1. Bellows 2. Inner Clamp 3. Clamp 11. Install clamp over small end of bellows. 12. Left side only Position leak detection pump and install mounting screws. 13. Thread tie rod jam nut onto inner tie rod far enough to install outer tie rod. 14. Install outer tie rod. Refer to following procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Outer Tie Rod > Page 6956 OUTER TIE ROD NOTE:Before installing the outer tie rod, make sure the jam nut is on inner tie rod and that it is installed far enough to install outer tie rod (Inner to Outer Tie Rod Jam Nut). 1. Using same amount of turns as counted during removal procedure, install outer tie rod onto inner tie rod (Inner To Outer Tie Rod Jam Nut). 1. Steering Knuckle 2. Tie Rod End 3. Crowfoot 4. Socket 5. Torque Wrench 2. Install outer tie rod end into steering knuckle. Start tie rod end to steering knuckle nut onto stud of outer tie rod end. While holding stud of tie rod end stationary, tighten tie rod end to steering knuckle nut using crowfoots foot wrench and socket nut to 75 N.m (55 ft. lbs.). 3. Snug tie rod jam nut at this time. Do not fully tighten to specifications. Tighten to specifications once toe is set in last step of procedure. 4. Install front wheel and tire assembly. See: Wheels and Tires 5. Lower vehicle. 6. Adjust front toe and tighten tie rod jam nut to 75 N.m (55 ft.lbs.). See: Alignment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications Ball Joint Nut ....................................................................................................................................... .................................................. 108 Nm (80 ft. lbs.) Wear Limit With the weight of the vehicle resting on the road wheels, grasp the special fitting cap on the bottom of the ball joint and with no mechanical assistance or added force, attempt to rotate the grease fitting. If the ball joint is worn, the grease fitting will rotate easily. If movement is noted, replacement of the control arm is recommended. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description and Operation > Lower Ball Joint Ball Joint: Description and Operation Lower Ball Joint LOWER BALL JOINT DESCRIPTION The ball joint is an integral part of the lower control arm. The ball joint has a tapered stud that is pressed into the aluminum knuckle. The ball joint stud is threaded on the end for a retainer nut. The ball joint has a non-vented seal boot. The seal boot has an integrated heat shield. The ball joint used in the lower control arm of this vehicle is a sealed-for-life ball joint and requires no maintenance lubrication. The ball joint has been lubricated-for-life during the manufacturing process. A special fitting cap is installed on the fill port. This cap must not be removed and replaced with a common zirc fitting. The special cap is there to eliminate the possibility of lubrication latter during the ball joints life, thus damaging the non-vented seal boot. NOTE: The ball joint does not require any type of additional lubrication for the life of the vehicle. No attempt should be made to ever add any lubrication to the lower ball joint. OPERATION The ball joint is a pivotal joint on the lower control arm that allows the knuckle to move up and down, and turn with ease. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description and Operation > Lower Ball Joint > Page 6963 Ball Joint: Description and Operation Lower Ball Joint Dust Cover - Front LOWER BALL JOINT SEAL BOOT - EXPORT DESCRIPTION The lower ball joint seal boot is a two piece unit. It consists of the seal boot, plus a separate shield that is located in a groove at the top of the seal boot. NOTE: The seal boot should only be replaced if damaged during vehicle service. The entire lower control arm should be replaced if the joint has been contaminated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description and Operation > Lower Ball Joint > Page 6964 Ball Joint: Description and Operation Lower Ball Joint Seal Boot - Export DESCRIPTION - EXPORT The lower ball joint seal boot is a two piece unit. It consists of the seal boot, plus a separate shield that is located in a groove at the top of the seal boot. NOTE: The seal boot should only be replaced if damaged during vehicle service. The entire lower control arm should be replaced if the joint has been contaminated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description and Operation > Page 6965 Ball Joint: Testing and Inspection DIAGNOSIS AND TESTING - LOWER BALL JOINT With the weight of the vehicle resting on the road wheels, grasp the special fitting cap on the bottom of the ball joint and with no mechanical assistance or added force, attempt to rotate the grease fitting. If the ball joint is worn, the grease fitting will rotate easily. If movement is noted, replacement of the control arm is recommended. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description and Operation > Page 6966 Ball Joint: Service and Repair REMOVAL - BALL JOINT SEAL BOOT 1. Remove steering knuckle from vehicle. 2. Using a screw driver or other suitable tool, pry the seal boot off of the ball joint. 3. Inspect the ball joint for evidence of dirt or water intrusion and wipe clean as necessary. If dirt or water intrusion is extreme and joint cannot be properly cleaned, the lower control arm will need to be replaced. REMOVAL - EXPORT 1. Remove steering knuckle from vehicle. 2. Remove shield from seal boot by gently pulling on it. 3. Using a screw driver or other suitable tool, pry seal boot off lower ball joint. INSTALLATION - BALL JOINT SEAL BOOT 1. Place a liberal dab of Mopers Wheel Bearing Grease around the base of the ball joint stem at the socket. 2. Install a NEW seal boot by hand as far as possible on the ball joint. Installation of the seal boot is to be with the shield positioned as shown. CAUTION: Do not use an arbor press to install the sealing boot on the ball joint. Damage to the sealing boot will occur if excessive pressure is applied to the sealing boot when it is being installed. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description and Operation > Page 6967 3. Place Installer, Special Tool 6758, over seal boot and squarely align it with bottom edge of seal boot. Apply hand pressure (or gently tap with a hammer) to Special Tool 6758 until seal boot is pressed squarely against top surface of lower control arm. 4. Wipe any grease off the ball joint stem using a clean shop towel with Mopers Brake Parts Cleaner applied to it. CAUTION: Do not attempt to install a normal grease zirc in the ball joint an lubricate the joint through the zirc fitting. 5. Reinstall steering knuckle on vehicle. INSTALLATION - EXPORT 1. Place a liberal dab of Mopers Wheel Bearing Grease around the base of the ball joint stem at the socket. 2. Install a NEW seal boot by hand as far as possible on the ball joint. CAUTION: Do not use an arbor press to install the sealing boot on the ball joint. Damage to the sealing boot will occur if excessive pressure is applied to the sealing boot when it is being installed. 3. Place Installer, Special Tool 6758, over seal boot and squarely align it with bottom edge of seal boot. Apply hand pressure to Special Tool 6758 until seal boot is pressed squarely against top surface of lower control arm. 4. Wipe any grease off the ball joint stem. 5. Place the shield over the top of the seal boot and stretch it into the groove at the top of the seal boot. CAUTION: Do not attempt to install a normal grease zirc in the ball joint and lubricate the joint through the zirc fitting. 6. Reinstall steering knuckle on vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Rear Bushing - Hydro Control Arm Bushing: Service and Repair Rear Bushing - Hydro DISASSEMBLY 1. Remove the lower control arm from the front suspension cradle. 2. Mount the lower control arm in a vise without using excessive clamping force. 3. Install Remover, Special Tool 8460, on hydrobushing as shown. Removal Pin, Special Tool 8460-3, must extend though hole in center of bushing rear. 4. Tighten forcing screw of Bridge (Special Tool 8460-1), removing bushing from lower control arm. ASSEMBLY CAUTION: Do not apply grease or any other type of lubricant to the arm stem where the bushing is to be mounted. Such action will reduce proper bushing adhesion to arm. 1. Secure lower control arm in a vise. NOTE: Hydro bushings and grooves on control arm stems are unique for right and left sides. Left side bushing master spline and control arm groove are on the top (when mounted on vehicle). Right side bushing master spline and control arm groove are on the bottom (when mounted on vehicle). 2. Align master spline on bushing inner sleeve with groove on lower control arm rear bushing stem. Start bushing on stem by hand. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Rear Bushing - Hydro > Page 6973 3. Install Remover/Installer, Special Tool 8460, over bushing and lower control arm as shown. Engage flange on lower control arm with tips of Bridge, Special Tool 8460-1 as shown. The contoured side of Installer Cup, Special Tool 8460-2, should be fitted up against rear of the bushing. 4. Begin to tighten forcing screw. As bushing nears lower control arm flange, place Spacer Plate, Special Tool 8460-4 between flange and bushing inner sleeve, straddling the stem as shown. 5. Install bushing up against Spacer Plate, tightening the bridge forcing screw with a torque wrench until approximately 50 Nm (37 ft. lbs.) torque is reached. This will properly space bushing on the stem in relation to the flange. 6. Back off the forcing screw and remove tool. 7. Install lower control arm on vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Rear Bushing - Hydro > Page 6974 Control Arm Bushing: Service and Repair Rear Bushing - Standard DISASSEMBLY 1. Remove the lower control arm from the front suspension cradle. 2. Mount the lower control arm in a vise without using excessive clamping force. 3. Using a sharp knife (such as a razor), slit the bushing lengthwise to allow its removal from the lower control arm. 4. Remove the bushing from the lower control arm. ASSEMBLY CAUTION: Do not apply grease or any other type of lubricant other than the silicone lubricant specified to the control arm bushing. 1. Apply Mopar Silicone Spray Lube or an equivalent, to the hole in lower control arm rear bushing. This will aid in the installation of the bushing on the lower control arm. 2. With the lower control arm held securely in a vise, install bushing on lower control arm. Install bushing by pushing and rocking the bushing until it is fully installed on lower control arm. Be sure that when bushing is installed it is past the upset on the end of the lower control arm. 3. The rear bushing of the lower control arm, when correctly installed, is to be positioned on the lower control arm as shown. 4. Install lower control arm on vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Specifications Front Cross-Member: Specifications Front Cradle Crossmember Mounting Bolts (M14) ............................................................................................................................. 163 Nm (120 ft. lbs.) Front Cradle Crossmember Reinforcement Bolts M14 ...................................................................................................................................................... ............................................ 153 Nm (113 ft. lbs.) M12 ....................................................................... ............................................................................................................................. 106 Nm (78 ft. lbs.) M10 ...................................................................................................................................................... ................................................ 61 Nm (45 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Specifications > Page 6979 Front Cross-Member: Description and Operation DESCRIPTION DESCRIPTION - FRONT CRADLE CROSSMEMBER This vehicle uses a one piece cast aluminum cradle for the front cradle crossmember. The cradle crossmember is used as the attaching points for the lower control arms, stabilizer bar and steering gear. The cradle also has the power steering hoses and the chassis brake tubes attached to it. WARNING: If a threaded hole in the suspension cradle needs to be repaired, only use the type of thread insert and installation procedure specified for this application. The threaded holes in the front cradle crossmember that are used for attachment of the lower control arm rear bushing retainer, power steering hose and chassis brake tubes can be repaired. The repair is done by the installation of a Heli-Coil(R) thread insert which has been specifically developed for this application. The procedure for installing the Heli-Coil(R) thread insert is detailed in the Service Procedures. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Procedures Front Cross-Member: Procedures DESCRIPTION - FRONT CRADLE CROSSMEMBER THREAD REPAIR WARNING: When performing this procedure use only the thread inserts which are specified in the Mopar Parts Catalog for this repair procedure. These thread inserts have been specifically developed for this application and use of other types of thread inserts can result in an inferior long term repair. The threaded holes in the front cradle crossmember, if damaged, can repaired by installing a Heli-Coil(R) thread insert. The threaded holes that are repairable using the thread insert, are the lower control arm rear bushing retainer mounting bolt holes, routing bracket attaching locations for the power steering hoses, and brake hose attachment holes. This repair procedure now allows the threaded holes in the cradle crossmember to be repaired, eliminating the need to replace the cradle crossmember if damage occurs to one of the threaded holes. The thread inserts for this application are specified by part number in the Mopar Parts Catalog. Do not use a substitute thread insert. The specific tools and equipment required to install the thread insert are listed below. Refer to the instructions included with the thread insert for the detailed procedure used for the installation of the thread insert. NOTE: The thread inserts for this application are for the repair of M8x1.25 and M10x1.5 threads. Be sure the correct tools are used for the required thread insert size. TOOL REQUIREMENT FOR M8x1.25 Thread - 8.3 mm (5/16 in.) Drill Bit - 120 degrees Countersink - Heli-Coil(R) Tap #4863-8 - Heli-Coil(R) Gage #4624-8 - Heli-Coil(R) Hand Inserting Tool 7751-8 - Needle Nose Pliers - For Removal Of Thread Insert Driving Tang TOOL REQUIREMENT FOR M10x1.5 Thread - 10.5 mm (25/64 in.) Drill Bit - 120 degrees Countersink - Heli-Coil(R) Tap #4863-10 - Heli-Coil(R) Gage #4624-10 - Heli-Coil(R) Hand Inserting Tool 7751-10 - Needle Nose Pliers - For Removal Of Thread Insert Driving Tang Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Procedures > Page 6982 Front Cross-Member: Removal and Replacement REMOVAL The front cradle crossmember must be installed in the design location to achieve proper front end suspension alignment. If the cradle crossmember is removed without applying reference marks on the frame rails, align the cradle crossmember according to the dimensions provided in this group. Fig. 20 NOTE: If the caged nuts in the frame rails become damaged and cannot be reused, a replacement nut can be obtained through Mopar(R) (Fig. 20). 1. Disconnect battery negative cable. 2. Remove steering column lower cover from instrument panel. 3. Remove steering column cover backing plate. Refer to Knee Diverter. 4. Position steering so front wheels are straight ahead. CAUTION: Do not rotate steering wheel after disengaging lower coupling from steering gear, damage to air bag clock spring can result. Fig. 21 5. Remove clinch bolt attaching steering column coupling to steering gear shaft (Fig. 21). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Procedures > Page 6983 6. Remove steering column coupling from telescoping steering gear shaft. 7. Hoist vehicle and support on safety stands. 8. Position a drain pan under power steering pump and oil return hose coupling. 9. Using a hose pinch-off pliers (C-4390), pinch power steering oil return hose off between the crossmember coupling and the pump. 10. Loosen hose clamp at the cradle crossmember coupling. 11. Disconnect return hose from metal tube. 12. While holding pressure relief valve nut on back of power steering pump, Remove flare nut attaching high pressure hose to back of pump. 13. Remove high pressure hose from pump. 14. Allow power steering fluid to drain into pan. 15. Remove bolts attaching anti-lock brake sensor leads to cradle crossmember. 16. Position anti-lock brake leads out of the way. 17. Disconnect stabilizer bar links from ends of stabilizer bar. 18. Disconnect lower ball joints from lower steering knuckles. Fig. 22 19. Remove the rear engine mount heat shield (Fig. 22). Fig. 23 20. Remove through bolt attaching rear engine mount to cradle crossmember (Fig. 23). 21. Using paint or grease pencil, mark outline of cradle crossmember on frame rails to aid installation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Procedures > Page 6984 Fig. 25 22. Support cradle crossmember on suitable lifting device (Fig. 25). Fig. 24 23. Remove bolts attaching crossmember to front frame rails (Fig. 24). 24. Remove cradle crossmember from vehicle (Fig. 25). INSTALLATION NOTE: If cradle crossmember requires replacement. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member > System Information > Service and Repair > Procedures > Page 6985 1. Support crossmember on suitable lifting device (Fig. 25). 2. Position crossmember to vehicle. 3. Loosely install bolts attaching cradle crossmember to front frame rails. 4. Place upper half of bushing on top of crossmember aligned to receive square tube protruding upward from lower bushing half. 5. Align crossmember to previously made marks on frame rails. 6. Tighten bolts attaching cradle crossmember to frame rails. 7. Install through bolt attaching rear engine mount to cradle crossmember (Fig. 23) and tighten to 68 N.m (50 ft.lbs.) torque. 8. Install the rear mount heat shield (Fig. 22). 9. Connect lower ball joints to steering knuckles. 10. Connect stabilizer bar links to ends of stabilizer bar. 11. Install bolts attaching anti-lock brake sensor leads to cradle crossmember. 12. Install high pressure hose to pump. 13. Connect return hose to metal tube. 14. Tighten hose clamp at the cradle crossmember coupling. 15. Remove pinch-off pliers. 16. Position steering so front wheels are straight ahead. 17. Install steering column coupling to telescoping steering gear shaft. 18. Install clinch bolt attaching steering column coupling to steering gear shaft. 19. Install steering column cover backing plate. 20. Install steering column lower cover from instrument panel. 21. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Front Cross-Member Bushing > System Information > Service and Repair Front Cross-Member Bushing: Service and Repair FRONT CROSSMEMBER MOUNT BUSHINGS REMOVAL 1. Using paint or grease pencil, mark outline of cradle crossmember on frame rails. 2. Loosen bolts attaching crossmember to frame rails. 3. Remove bolt on bushing that requires replacement. 4. Allow cradle crossmember to drop down enough to gain clearance for bushing removal. 5. Remove bushing from vehicle. INSTALLATION 1. Apply rubber lubrication or soap to replacement bushing. 2. Insert lower half of bushing into square hole in cradle crossmember. 3. Place upper half of bushing on top of crossmember aligned to receive square tube protruding upward from lower bushing half. 4. Squeeze bushing halves together to ensure they are properly mated. 5. Lift cradle crossmember upward to close gap between the bushing and frame. 6. Verify that lower bushing is fully seated into cradle crossmember and upper bushing. 7. Install bolt attaching bushing and crossmember to frame rail hand tight. 8. Align cradle crossmember to reference marks on frame rails. 9. Tighten cradle crossmember to frame rails attaching bolts to 163 N.m (120 ft.lbs.) torque. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications Lateral Stabilizer Rod: Specifications Track Bar Bracket-to-Body Mount Bolts ................................................................................................................................................. 61 Nm (45 ft. lbs.) Track Bar Pivot Bolts ........................................................................................................................... ................................................... 95 Nm (70 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 6992 Lateral Stabilizer Rod: Description and Operation TRACK BAR DESCRIPTION On front-wheel-drive applications of this vehicle that are equipped with single leaf rear springs, a track bar is used on the rear axle. The track bar connects the rear axle to the frame/body of the vehicle. The track bar is isolated from the body of the vehicle by an isolator bushing located in each end of the track bar. OPERATION The track bar prevents excessive side-to-side movement of the rear axle. The track bar is used to keep the location of the axle in the correct position for optimum handling and control of the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 6993 Lateral Stabilizer Rod: Service and Repair TRACK BAR REMOVAL 1. Remove the nut and bolt mounting the track bar to the rear axle. 2. Remove the nut and bolt attaching the track bar to the track bar mount on the body of the vehicle. Remove the track bar from the track bar mount. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Specifications > Page 6994 1. Install the track bar first into the body mount for the track bar. Install the track bar bolt with the head of the bolt facing toward the rear of the vehicle. Do not tighten. 2. Install the track bar into its mounting bracket on the rear axle. Install the track bar bolt with the head of the bolt facing toward the rear of the vehicle. Do not tighten. 3. Lower the vehicle to the ground until the full weight of the vehicle is supported by the wheels. Tighten both track bar attaching bolts to a torque of 95 Nm (70 ft. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Bushing: > 02-003-05 > Mar > 05 > Suspension - Front Suspension Rattle/Knocking Sound Stabilizer Bushing: Customer Interest Suspension - Front Suspension Rattle/Knocking Sound NUMBER: 02-003-05 GROUP: Suspension DATE: March 16, 2005 SUBJECT: Rattle/knocking Sound From The Front Suspension OVERVIEW: This bulletin involves replacing the front sway bar bushings at the frame. MODELS: 2001 - 2005 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to RS vehicles built on or before February 1, 2005 (MDH 0201XX) and RG vehicles built on or before March 1, 2005 (MDH O301XX). SYMPTOM/CONDITION: The vehicle may exhibit a rattle/knocking sound which may be heard at low speeds while driving over bumps and/or road surfaces with minor fluctuations. NOTE: On RS and RG vehicles built on or after August 16, 2003 (MDH0816XX), this sound is very similar to the sway bar link rattle described in service bulletin 02-001-05. It is important that the sway bar bushings are replaced BEFORE replacing the sway bar links. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Replace both front sway bar bushings at the frame. Refer to the detailed removal and installation procedures available in TechCONNECT, under: Service Info, 2 - Suspension, Front, Bushings, Removal and Installation. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Bushing: > 02-003-05 > Mar > 05 > Suspension - Front Suspension Rattle/Knocking Sound > Page 7004 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Bushing: > 02-003-05 > Mar > 05 > Suspension - Front Suspension Rattle/Knocking Sound Stabilizer Bushing: All Technical Service Bulletins Suspension - Front Suspension Rattle/Knocking Sound NUMBER: 02-003-05 GROUP: Suspension DATE: March 16, 2005 SUBJECT: Rattle/knocking Sound From The Front Suspension OVERVIEW: This bulletin involves replacing the front sway bar bushings at the frame. MODELS: 2001 - 2005 (RS) Town & Country/Caravan/Voyager 2001 - 2005 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to RS vehicles built on or before February 1, 2005 (MDH 0201XX) and RG vehicles built on or before March 1, 2005 (MDH O301XX). SYMPTOM/CONDITION: The vehicle may exhibit a rattle/knocking sound which may be heard at low speeds while driving over bumps and/or road surfaces with minor fluctuations. NOTE: On RS and RG vehicles built on or after August 16, 2003 (MDH0816XX), this sound is very similar to the sway bar link rattle described in service bulletin 02-001-05. It is important that the sway bar bushings are replaced BEFORE replacing the sway bar links. DIAGNOSIS: If the vehicle operator describes the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Replace both front sway bar bushings at the frame. Refer to the detailed removal and installation procedures available in TechCONNECT, under: Service Info, 2 - Suspension, Front, Bushings, Removal and Installation. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Bushing: > 02-003-05 > Mar > 05 > Suspension - Front Suspension Rattle/Knocking Sound > Page 7010 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > Page 7011 Stabilizer Bushing: Specifications Stabilizer Bar Bushing Retainer Bolts Front .................................................................................................................................................... ................................................. 68 Nm (50 ft. lbs.) Rear ..................................................................... ................................................................................................................................. 61 Nm (45 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Technical Service Bulletins > Page 7012 Stabilizer Bushing: Service and Repair REMOVAL 1. Raise Vehicle. 2. Remove the 2 bolts fastening the emission leak detection pump to the cradle crossmember reinforcement. 3. Move the leak detection pump to the side allowing access to the stabilizer bar cushion retainers. 4. Remove the nut and bolt securing each stabilizer bar cushion retainer to the cradle crossmember and remove the retainers. 5. Remove each stabilizer bar cushion from the stabilizer bar by opening the slit in the cushion and peeling it off the stabilizer bar. INSTALLATION 1. Install each new cushion on stabilizer bar by spreading cushion at slit and forcing it onto stabilizer bar. NOTE: Cushions must be installed on stabilizer bar so the square corner of the bushing will be down and slit in cushion will be facing the rear of the vehicle when the stabilizer bar is installed. 2. Place stabilizer bar into mounted position with cushions properly aligned. 3. Hook each retainer into cradle crossmember mounting hole and over cushion. 4. Install each mounting bolt from rear of cradle crossmember through retainer. Install the two nuts and tighten to 68 Nm (50 ft. lbs.) torque. 5. Reattach emission leak detection pump to cradle crossmember reinforcement with two mounting bolts. 6. Lower the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications Stabilizer Link: Specifications Stabilizer Bar Link Nuts Front .................................................................................................................................................... ................................................. 88 Nm (65 ft. lbs.) Rear ..................................................................... ................................................................................................................................. 61 Nm (45 ft. lbs.) Rear Stabilizer Bar Link Frame Bracket Mounting Bolts ........................................................................................................................ 61 Nm (45 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Description and Operation Front Subframe: Description and Operation DESCRIPTION DESCRIPTION - FRONT CRADLE CROSSMEMBER This vehicle uses a one piece cast aluminum cradle for the front cradle crossmember. The cradle crossmember is used as the attaching points for the lower control arms, stabilizer bar and steering gear. The cradle also has the power steering hoses and the chassis brake tubes attached to it. WARNING: If a threaded hole in the suspension cradle needs to be repaired, only use the type of thread insert and installation procedure specified for this application. The threaded holes in the front cradle crossmember that are used for attachment of the lower control arm rear bushing retainer, power steering hose and chassis brake tubes can be repaired. The repair is done by the installation of a Heli-Coil(R) thread insert which has been specifically developed for this application. The procedure for installing the Heli-Coil(R) thread insert is detailed in the Service Procedures section in this group of the service manual. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Procedures Front Subframe: Procedures DESCRIPTION - FRONT CRADLE CROSSMEMBER THREAD REPAIR WARNING: When performing this procedure use only the thread inserts which are specified in the Mopar Parts Catalog for this repair procedure. These thread inserts have been specifically developed for this application and use of other types of thread inserts can result in an inferior long term repair. The threaded holes in the front cradle crossmember, if damaged, can repaired by installing a Heli-Coil(R) thread insert. The threaded holes that are repairable using the thread insert, are the lower control arm rear bushing retainer mounting bolt holes, routing bracket attaching locations for the power steering hoses, and brake hose attachment holes. This repair procedure now allows the threaded holes in the cradle crossmember to be repaired, eliminating the need to replace the cradle crossmember if damage occurs to one of the threaded holes. The thread inserts for this application are specified by part number in the Mopar Parts Catalog. Do not use a substitute thread insert. The specific tools and equipment required to install the thread insert are listed below. Refer to the instructions included with the thread insert for the detailed procedure used for the installation of the thread insert. NOTE: The thread inserts for this application are for the repair of M8x1.25 and M10x1.5 threads. Be sure the correct tools are used for the required thread insert size. TOOL REQUIREMENT FOR M8x1.25 Thread - 8.3 mm (5/16 in.) Drill Bit - 120 degrees Countersink - Heli-Coil(R) Tap #4863-8 - Heli-Coil(R) Gage #4624-8 - Heli-Coil(R) Hand Inserting Tool 7751-8 - Needle Nose Pliers - For Removal Of Thread Insert Driving Tang TOOL REQUIREMENT FOR M10x1.5 Thread - 10.5 mm (25/64 in.) Drill Bit - 120 degrees Countersink - Heli-Coil(R) Tap #4863-10 - Heli-Coil(R) Gage #4624-10 - Heli-Coil(R) Hand Inserting Tool 7751-10 - Needle Nose Pliers - For Removal Of Thread Insert Driving Tang Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Procedures > Page 7022 Front Subframe: Removal and Replacement REMOVAL The front cradle crossmember must be installed in the design location to achieve proper front end suspension alignment. If the cradle crossmember is removed without applying reference marks on the frame rails, align the cradle crossmember according to the dimensions provided in this group. Fig. 20 NOTE: If the caged nuts in the frame rails become damaged and cannot be reused, a replacement nut can be obtained through Mopar(R) (Fig. 20). 1. Disconnect battery negative cable. 2. Remove steering column lower cover from instrument panel. 3. Remove steering column cover backing plate. Refer to knee Diverter. 4. Position steering so front wheels are straight ahead. CAUTION: Do not rotate steering wheel after disengaging lower coupling from steering gear, damage to air bag clock spring can result. Fig. 21 5. Remove clinch bolt attaching steering column coupling to steering gear shaft (Fig. 21). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Procedures > Page 7023 6. Remove steering column coupling from telescoping steering gear shaft. 7. Hoist vehicle and support on safety stands. 8. Position a drain pan under power steering pump and oil return hose coupling. 9. Using a hose pinch-off pliers (C-4390), pinch power steering oil return hose off between the crossmember coupling and the pump. 10. Loosen hose clamp at the cradle crossmember coupling. 11. Disconnect return hose from metal tube. 12. While holding pressure relief valve nut on back of power steering pump, Remove flare nut attaching high pressure hose to back of pump. 13. Remove high pressure hose from pump. 14. Allow power steering fluid to drain into pan. 15. Remove bolts attaching anti-lock brake sensor leads to cradle crossmember. 16. Position anti-lock brake leads out of the way. 17. Disconnect stabilizer bar links from ends of stabilizer bar. 18. Disconnect lower ball joints from lower steering knuckles. Fig. 22 19. Remove the rear engine mount heat shield (Fig. 22). Fig. 23 20. Remove through bolt attaching rear engine mount to cradle crossmember (Fig. 23). 21. Using paint or grease pencil, mark outline of cradle crossmember on frame rails to aid installation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Procedures > Page 7024 Fig. 25 22. Support cradle crossmember on suitable lifting device (Fig. 25). Fig. 24 23. Remove bolts attaching crossmember to front frame rails (Fig. 24). 24. Remove cradle crossmember from vehicle (Fig. 25). INSTALLATION NOTE: If cradle crossmember requires replacement. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Procedures > Page 7025 1. Support crossmember on suitable lifting device (Fig. 25). 2. Position crossmember to vehicle. 3. Loosely install bolts attaching cradle crossmember to front frame rails. 4. Place upper half of bushing on top of crossmember aligned to receive square tube protruding upward from lower bushing half. 5. Align crossmember to previously made marks on frame rails. 6. Tighten bolts attaching cradle crossmember to frame rails. 7. Install through bolt attaching rear engine mount to cradle crossmember (Fig. 23) and tighten to 68 N.m (50 ft.lbs.) torque. 8. Install the rear mount heat shield (Fig. 22). 9. Connect lower ball joints to steering knuckles. 10. Connect stabilizer bar links to ends of stabilizer bar. 11. Install bolts attaching anti-lock brake sensor leads to cradle crossmember. 12. Install high pressure hose to pump. 13. Connect return hose to metal tube. 14. Tighten hose clamp at the cradle crossmember coupling. 15. Remove pinch-off pliers. 16. Position steering so front wheels are straight ahead. 17. Install steering column coupling to telescoping steering gear shaft. 18. Install clinch bolt attaching steering column coupling to steering gear shaft. 19. Install steering column cover backing plate. 20. Install steering column lower cover from instrument panel. 21. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe Mount > System Information > Service and Repair Front Subframe Mount: Service and Repair FRONT CROSSMEMBER MOUNT BUSHINGS REMOVAL 1. Using paint or grease pencil, mark outline of cradle crossmember on frame rails. 2. Loosen bolts attaching crossmember to frame rails. 3. Remove bolt on bushing that requires replacement. 4. Allow cradle crossmember to drop down enough to gain clearance for bushing removal. 5. Remove bushing from vehicle. INSTALLATION 1. Apply rubber lubrication or soap to replacement bushing. 2. Insert lower half of bushing into square hole in cradle crossmember. 3. Place upper half of bushing on top of crossmember aligned to receive square tube protruding upward from lower bushing half. 4. Squeeze bushing halves together to ensure they are properly mated. 5. Lift cradle crossmember upward to close gap between the bushing and frame. 6. Verify that lower bushing is fully seated into cradle crossmember and upper bushing. 7. Install bolt attaching bushing and crossmember to frame rail hand tight. 8. Align cradle crossmember to reference marks on frame rails. 9. Tighten cradle crossmember to frame rails attaching bolts to 163 N.m (120 ft.lbs.) torque. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Leaf Spring Suspension Spring ( Coil / Leaf ): Specifications Leaf Spring Leaf Spring Front Mount-to-Body Bolts .................................................................................................................................................. 61 Nm (45 ft. lbs.) Leaf Spring Front Pivot Bolt ................................................................................................................. ............................................... 156 Nm (115 ft. lbs.) Leaf Spring Plate-to-Axle Bolts ............................................................................................................ ................................................... 95 Nm (70 ft. lbs.) Leaf Spring Rear Mount-to-Body Bolts ................................................................................................................................................... 61 Nm (45 ft. lbs.) Leaf Spring Shackle Plate Nuts ........................................................................................................... ..................................................... 61 Nm (45 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Leaf Spring > Page 7033 Suspension Spring ( Coil / Leaf ): Specifications Leaf Spring Shackle Leaf Spring Shackle Plate Nuts ........................................................................................................... ..................................................... 61 Nm (45 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Page 7034 Suspension Spring ( Coil / Leaf ): Description and Operation DESCRIPTION The leaf springs used on the rear suspension of this vehicle are of either a mono-leaf or multi-leaf design depending on model and options. Since the rear springs come in various designs and rates, be sure the correct spring is in use. OPERATION The leaf spring controls ride quality and maintains ride height. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring REMOVAL 1. Raise vehicle on frame-contact hoist as follows: a. Position the hoist arm supporting the corner of the vehicle to be serviced against a block of wood placed on the body sill as shown. b. Position the remaining hoist arms at each corner of the vehicle in the normal fashion. c. Raise the vehicle to a comfortable working level. 2. Position an under-hoist utility jack or transmission jack under rear axle toward the side needing spring replacement. Jack pad should just contact axle. 3. Remove the shock absorber lower mounting bolt. NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack. If shock absorber bolt deflects downward during removal, lower axle by adjusting support jack (or by pulling on axle). 4. Using 2 jack stands positioned under the outer ends of the axle, raise the axle enough to remove the weight of the axle from the rear springs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring > Page 7037 5. Loosen and remove the spring plate bolts from the rear axle. 6. Remove the spring plate from the rear axle and the leaf spring. 7. Using the jack stands slowly lower the rear axle, permitting the rear springs to hang free. 8. Loosen and remove the 4 bolts securing the front mount of the leaf spring to the vehicle. 9. Loosen and remove the nuts from the spring hanger for the rear leaf spring. Then remove the hanger plate from the hanger and remove the spring from the spring hanger. 10. Remove the leaf spring from the vehicle. 11. Loosen and remove the pivot bolt from the front mount of the rear leaf spring. Remove mount. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring > Page 7038 INSTALLATION 1. Assemble front spring mount to front of spring eye and install pivot bolt and nut. Do not tighten at this time. CAUTION: Pivot bolt must face inboard to prevent structural damage during installation of spring. 2. Raise front of spring and install four mounting bolts. Tighten bolts to 61 Nm (45 ft. lbs.) torque. 3. Install rear of spring onto rear spring shackle. Install shackle plate. Do not tighten. 4. Verify lower leaf spring isolator is in position. 5. Raise axle into correct position on leaf spring with axle centered under spring locator post. 6. Verify that the leaf spring isolator is correctly positioned in the spring plate. 7. Install spring plate in position on the spring. 8. Install spring plate bolts. Tighten bolts to 95 Nm (70 ft. lbs.) torque. 9. Install lower shock absorber bolt. Do not tighten at this time. 10. Remove jack under axle. 11. Lower the vehicle and remove hoist arms and block of wood from under vehicle. CAUTION: The following sequence must be followed when tightening the pin nuts on the rear hanger for the rear leaf spring. First the hanger pin nuts must be tightened to the specified torque shown. Then tighten the retaining bolts for the inner to outer half of the spring hanger to the torque specification listed. This sequence must be followed to properly seat the bushings into the springs and to avoid bending the spring hanger. 12. Tighten the spring front pivot bolt to 156 Nm (115 ft. lbs.) torque. 13. Tighten rear spring shackle pin nuts to 61 Nm (45 ft. lbs.) torque. 14. Tighten rear spring shackle inner to outer half retaining bolts to 61 Nm (45 ft. lbs.) torque. 15. Tighten the lower shock absorber mounting bolt to 102 Nm (75 ft. lbs.) torque. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring > Page 7039 Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Bushing REMOVAL 1. Raise vehicle on frame-contact hoist as follows: a. Position the hoist arm supporting the corner of the vehicle to be serviced against a block of wood placed on the body sill as shown. b. Position the remaining hoist arms at each corner of the vehicle in the normal fashion. c. Raise the vehicle to a comfortable working level. 2. Position an under-hoist utility jack or transmission jack under rear axle toward the side needing bushing replacement. Jack pad should just contact axle. 3. Remove shock absorber lower mounting bolt. NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack. If shock absorber bolt deflects downward during removal, lower axle by adjusting support jack (or by pulling on axle). 4. Remove four bolts securing leaf spring front mounting bracket to the body. 5. Using jack, slowly lower rear axle, permitting the forward end of rear spring to hang down. Lower it enough to allow access to spring pivot bolt. It may be necessary to place a wooden block between the spring and vehicle to hold forward end of the spring in place. 6. Remove leaf spring forward pivot bolt, then remove mounting bracket. 7. Straighten the retainer tabs on the bushing. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring > Page 7040 8. Place Remover/Installer, Special Tool 8459 on leaf spring and bushing as shown and tighten Set Screw securing Remover Plate to tool threaded shaft. 9. Tighten nut, removing bushing from spring eye. 10. Remove the tool from spring, then remove bushing from tool. INSTALLATION 1. Install by hand NEW bushing in left side of leaf spring eye. 2. Place Remover/Installer, Special Tool 8459 on leaf spring and bushing as shown and tighten Set Screw securing Installer Plate (8459-3) to tool threaded shaft. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring > Page 7041 3. Tighten nut, installing bushing in spring eye. Tighten nut until there is approximately a 1 mm gap between the bushing flange and the spring eye. Do not bottom the flange against the spring eye. 4. Remove Remover/Installer from the bushing and leaf spring. 5. Bend the retainer tabs on bushing outward against spring eye. 6. Position spring mounting bracket over spring eye and install pivot bolt through center of bushing from the outboard side. NOTE: The pivot bolt must be installed from the outboard side to allow proper bracket to body mounting. 7. Install the nut on the pivot bolt and lightly tighten. Do not fully tighten bolt at this time. 8. Raise the under-hoist utility jack or transmission jack, guiding the forward mounting bracket into place against the body. It may help to use a drift punch placed through the hole centered between the mounting bolt holes in the bracket and the pilot hole in the body of the vehicle as a guide. When the four mounting bolt holes line up with their threads in the body, Install the mounting bolts. Tighten the four mounting bolts to 61 Nm (45 ft. lbs.) torque. 9. Raise or lower the jack until shock absorber lower eye aligns with threads in axle housing. Install shock absorber lower mounting bolt. Do not fully tighten bolt at this time. 10. Lower the vehicle and remove hoist arms and block of wood from under vehicle. 11. Tighten the spring front pivot bolt to 156 Nm (115 ft. lbs.) torque. 12. Tighten the lower shock absorber mounting bolt to 88 Nm (65 ft. lbs.) torque. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring > Page 7042 Suspension Spring ( Coil / Leaf ): Service and Repair Spring Mounts Front REMOVAL 1. Raise vehicle on frame-contact hoist as follows: a. Position the hoist arm supporting the corner of the vehicle to be serviced against a block of wood placed on the body sill as shown. b. Position the remaining hoist arms at each corner of the vehicle in the normal fashion. c. Raise the vehicle to a comfortable working level. 2. Position an under-hoist utility jack or transmission jack under rear axle toward the side needing bushing replacement. Jack pad should just contact axle. 3. Remove shock absorber lower mounting bolt. NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack. If shock absorber bolt deflects downward during removal, lower axle by adjusting support jack (or by pulling on axle). 4. Remove four bolts securing leaf spring front mounting bracket to the body. 5. Using jack, slowly lower rear axle, permitting the forward end of rear spring to hang down. Lower it enough to allow access to spring pivot bolt. It may be necessary to place a wooden block between the spring and vehicle to hold forward end of the spring in place. 6. Remove leaf spring forward pivot bolt, then remove mounting bracket. INSTALLATION 1. Position spring mounting bracket over spring eye and install pivot bolt through center of bushing from the outboard side. NOTE: The pivot bolt must be installed from the outboard side to allow proper bracket to body mounting. 2. Install the nut on the pivot bolt and lightly tighten. Do not fully tighten bolt at this time. 3. Raise the under-hoist utility jack or transmission jack, guiding the forward mounting bracket into place against the body. It may help to use a drift punch placed through the hole centered between the mounting bolt holes in the bracket and the pilot hole in the body of the vehicle as a guide. When the four mounting bolt holes line up with their threads in the body, Install the mounting bolts. Tighten the four mounting bolts to 61 Nm (45 ft. lbs.) torque. 4. Raise or lower the jack until shock absorber lower eye aligns with threads in axle housing. Install shock absorber lower mounting bolt. Do not fully tighten bolt at this time. 5. Lower the vehicle and remove hoist arms and block of wood from under vehicle. 6. Tighten the spring front pivot bolt to 156 Nm (115 ft. lbs.) torque. 7. Tighten the lower shock absorber mounting bolt to 88 Nm (65 ft. lbs.) torque. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring > Page 7043 Suspension Spring ( Coil / Leaf ): Service and Repair Spring Mounts Rear REMOVAL 1. Remove the attaching nuts and bolts from the leaf spring rear shackle. 2. Install a jackstand under the side of the axle having the leaf spring mount removed. Using the jackstand, support the weight of the axle and leaf spring. 3. Remove the lower mounting bolt from the shock absorber. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Leaf Spring > Page 7044 4. Remove the bolts attaching the leaf spring rear mount to the body of the vehicle. 5. Lower the jackstand and the rear of the leaf spring. Remove the shackle from the leaf spring bushing. INSTALLATION CAUTION: The following sequence must be followed when tightening the pin nuts on the rear hanger for the rear leaf spring. First the hanger pin nuts must be tightened to the specified torque. Then tighten the retaining bolts for the inner to outer half of the spring hanger to the specified torque. This sequence must be followed to avoid bending the spring hanger. 1. For installation, reverse removal procedure. Do not tighten rear spring shackle nuts fully until vehicle is lowered and the full vehicle weight is applied to the rear wheels. Tighten rear spring mount bolts to 61 Nm (45 ft. lbs.). Tighten shackle nuts to 61 Nm (45 ft. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-004-05 > May > 05 > Suspension - Front Strut Squeaking/Squawking Sound Suspension Strut / Shock Absorber: Customer Interest Suspension - Front Strut Squeaking/Squawking Sound NUMBER: 02-004-05 GROUP: Chassis DATE: May 27, 2005 SUBJECT: Creaking/Squawking Sound From Front Strut Area OVERVIEW: This bulletin involves applying lubricant to the jounce bumper of both front struts. MODELS: 2004 - 2005 (CS) Pacifica 2001 - 2005 (RS/RG) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A creaking, squawking, squeaking, grinding, groaning sound from the front strut area while turning in either direction during low speed parking lot maneuvers. DIAGNOSIS: 1. Raise the vehicle on a suitable hoist so that the front wheels hang free. 2. Locate the front strut dust boot and rotate the dust boot fore and aft or move side to side. 3. If the sound is present, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Using the detailed service information available in TechCONNECT, remove and disassemble the left strut assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-004-05 > May > 05 > Suspension - Front Strut Squeaking/Squawking Sound > Page 7053 2. Apply a liberal amount of Nye Grease, p/n 05019061AA, to areas of the jounce bumper as illustrated (Fig. 1). NOTE: In the figure below the small jounce bumper is used in CS and Short Wheel Base (SWB) RS/RG vehicles. The larger jounce bumper is used in Long Wheel Base (LWB) RS/RG vehicles. 3. Using the detailed service information available in TechCONNECT, assemble and install the left strut assembly in the vehicle. 4. Repeat Step #1 through Step #3 on the right side of the vehicle. 5. Verify front end alignment. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-004-05 > May > 05 > Suspension - Front Strut Squeaking/Squawking Sound Suspension Strut / Shock Absorber: All Technical Service Bulletins Suspension - Front Strut Squeaking/Squawking Sound NUMBER: 02-004-05 GROUP: Chassis DATE: May 27, 2005 SUBJECT: Creaking/Squawking Sound From Front Strut Area OVERVIEW: This bulletin involves applying lubricant to the jounce bumper of both front struts. MODELS: 2004 - 2005 (CS) Pacifica 2001 - 2005 (RS/RG) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: A creaking, squawking, squeaking, grinding, groaning sound from the front strut area while turning in either direction during low speed parking lot maneuvers. DIAGNOSIS: 1. Raise the vehicle on a suitable hoist so that the front wheels hang free. 2. Locate the front strut dust boot and rotate the dust boot fore and aft or move side to side. 3. If the sound is present, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Using the detailed service information available in TechCONNECT, remove and disassemble the left strut assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 02-004-05 > May > 05 > Suspension - Front Strut Squeaking/Squawking Sound > Page 7059 2. Apply a liberal amount of Nye Grease, p/n 05019061AA, to areas of the jounce bumper as illustrated (Fig. 1). NOTE: In the figure below the small jounce bumper is used in CS and Short Wheel Base (SWB) RS/RG vehicles. The larger jounce bumper is used in Long Wheel Base (LWB) RS/RG vehicles. 3. Using the detailed service information available in TechCONNECT, assemble and install the left strut assembly in the vehicle. 4. Repeat Step #1 through Step #3 on the right side of the vehicle. 5. Verify front end alignment. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber Suspension Strut / Shock Absorber: Specifications Shock Absorber Shock Absorber Mounting Bolts .............................................................................................................................................................. 68 Nm (65 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber > Page 7062 Suspension Strut / Shock Absorber: Specifications Strut Strut Body/Tower Mounting Nuts ......................................................................................................................................................... 28 Nm (250 in. lbs.) Strut Clevis-to-Knuckle Nuts ................................................................................................................................................ 81 Nm (60 ft. lbs.) + 90 ° turn Strut Shaft Nut ..................................................................................................................................... .................................................. 100 Nm (75 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Rear Shock Absorber Suspension Strut / Shock Absorber: Description and Operation Rear Shock Absorber DESCRIPTION There is one shock absorber on each side of the rear suspension. The top of each shock absorber is bolted to the frame rail. The bottom of each shock absorber is bolted to the rear axle. This vehicle is available with either standard type or load-leveling shock absorbers. On the exterior, load-leveling shock absorbers are larger in diameter than standard shock absorbers. The load-leveling shock absorbers mount the same as the standard shock absorbers. OPERATION The shock absorber dampens jounce and rebound motions of the spring and suspension. Each load-leveling shock absorber is a self-leveling, self-contained vehicle leveling system and shock absorber combined. It does not require an external compressor, hoses, or height leveling sensors. All the height leveling sensors, hydraulic pump, etc., are contained inside the shock absorber. It uses road inputs (bumps, stops, starts, turns, acceleration, deceleration, etc.) to activate pumping, which results in the extension and compression of the shock absorber. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Rear Shock Absorber > Page 7065 Suspension Strut / Shock Absorber: Description and Operation Front Suspension Strut Assembly Description DESCRIPTION A MacPherson type strut assembly is used in place of a conventional front suspension's upper control arm and upper ball joint. The bottom of the strut mounts directly to the steering knuckle using two bolts and nuts going through the strut clevis bracket and steering knuckle. The top of the strut mounts directly to the strut tower of the vehicle using the threaded studs on the strut assemblies upper mount. The strut assembly includes the components listed in the figure. Each component is serviced by removing the strut assembly from the vehicle and disassembling it. The coil springs are side-oriented. Springs on the left side of the vehicle have a left-hand wind top-to-bottom while springs on the right side have a right hand wind top-to-bottom. This helps provide better vehicle stability during jounce and rebound maneuvers of the front suspension. Left and right springs must not be interchanged. Coil springs are rated separately for each corner or side of the vehicle depending on optional equipment and type of vehicle service. If the coil springs require replacement, be sure that the springs are replaced with springs meeting the correct load rating and spring rate for the vehicle and its specific options. OPERATION The strut assembly cushions the ride of the vehicle, controlling vibration, along with jounce and rebound of the suspension. The coil spring controls ride quality and maintains proper ride height. The spring isolators isolate the coil spring at the top and bottom from coming into metal-to-metal contact with the upper seat and strut. The jounce bumper limits suspension travel and metal-to-metal contact under full jounce condition. The strut dampens jounce and rebound motions of the coil spring and suspension. During steering maneuvers, the strut assembly (through a pivot bearing in the upper strut mount) and steering knuckle (through the lower ball joint) turn as an assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Description and Operation > Page 7066 Suspension Strut / Shock Absorber: Testing and Inspection STRUT ASSEMBLY 1. Inspect for damaged or broken coil springs. 2. Inspect for torn or damaged strut assembly dust boots. 3. Inspect the coil spring isolator on the lower spring seat for any signs of damage or deterioration. 4. Lift dust boot and inspect strut assembly for evidence of fluid running from the upper end of fluid reservoir. (Actual leakage will be a stream of fluid running down the side and dripping off lower end of unit). A slight amount of seepage between the strut rod and strut shaft seal is not unusual and does not affect performance of the strut assembly. Also inspect jounce bumpers for signs of damage or deterioration. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber Suspension Strut / Shock Absorber: Service and Repair Shock Absorber REMOVAL - SHOCK ABSORBER 1. Raise vehicle. 2. Support the rear axle of the vehicle using 2 jackstands positioned at the outer ends of the axle. NOTE: If the shock absorber lower mounting bolt deflects upward during removal, raise axle by adjusting the support jack. If the lower shock absorber bolt deflects downward during removal, lower the axle by adjusting the support jack. 3. Remove the shock absorber lower mounting bolt. 4. While holding shock absorber, remove the shock absorber upper mounting bolt and shock absorber. DISASSEMBLY - SHOCK ABSORBER (UPPER BUSHING) NOTE: This procedure applies to load-leveling shock absorbers only. 1. Remove the shock absorber from the vehicle. 2. Install the Receiver, Special Tool 8526-1, into the cup of the Ball Joint Press, Special Tool C-4212F, and tighten the set screw. Install the Driver, Special Tool 8526-2, on the tip of the Ball Joint Press screw drive as shown. NOTE: It works well to place the Ball Joint Press, Special Tool C-4212F, in a bench vise as shown to perform this procedure. 3. Place the shock absorber upper mounting eye in the Receiver so the notch in the Receiver clears the shock absorber body. 4. Tighten the screw drive until the Driver contacts the outer circumference of the bushing evenly. Continue to tighten the screw drive until the bushing is pressed completely out of the shock absorber eye and into the Receiver. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber > Page 7069 5. Back off the screw drive and remove the bushing from the Receiver. ASSEMBLY - SHOCK ABSORBER (UPPER BUSHING) NOTE: This procedure applies to load-leveling shock absorbers only. 1. Install the Receiver, Special Tool 8526-1, into the cup of the Ball Joint Press, Special Tool C-4212F, and tighten the set screw. Install the Driver, Special Tool 8526-2, on the tip of the Ball Joint Press screw drive as shown. Position the Driver this way to seat the bushing to its correct depth. 2. Place the shock absorber upper mounting eye in the Receiver so the notch in the Receiver clears the shock absorber body. 3. Position the bushing between the shock absorber eye and the Driver. Tighten the screw drive until the Driver, bushing, and shock absorber eye are touching and squarely aligned. 4. Press the bushing into the shock absorber eye until the Driver bottoms against the face of the eye. 5. Back off the Ball Joint Press screw drive and remove the shock absorber from the press. 6. Install the shock absorber on the vehicle. INSTALLATION - SHOCK ABSORBER 1. While holding shock absorber in position against the frame rail, install the shock absorber upper mounting bolt. 2. Install the shock absorber lower mounting bolt securing the lower end of the shock absorber to the axle. 3. Remove the support jack. 4. Lower the vehicle to the ground so the full curb weight of the vehicle is supported by the suspension. 5. Tighten the upper and lower shock absorber mounting bolt to a torque of 88 Nm (65 ft. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber > Page 7070 Suspension Strut / Shock Absorber: Service and Repair Strut Assembly REMOVAL WARNING: DO NOT REMOVE THE NUT FROM THE STRUT ROD WHILE STRUT ASSEMBLY IS INSTALLED IN VEHICLE, OR BEFORE STRUT ASSEMBLY SPRING IS COMPRESSED. 1. Raise the vehicle. 2. Remove the wheel and tire assembly from location on front of vehicle requiring strut removal. 3. If both strut assemblies are to be removed, mark the strut assemblies right or left according to which side of the vehicle they were removed from. 4. Remove the hydraulic brake hose routing bracket and the speed sensor cable routing bracket from the strut damper brackets. CAUTION: When removing the nut from the stud of the stabilizer bar link, do not allow the stud to rotate in it's socket. Hold the stud from rotating by placing an open-end wrench on the flat machined into the stud. 5. Remove the stabilizer bar link from the bracket on the strut assembly. To do so, place an open-end wrench on the flat machined into the link's mounting stud, then remove the nut while holding the wrench in place. Push the stud out of the bracket. CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during removal. Remove nuts while holding bolts stationary in the steering knuckles. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber > Page 7071 6. Remove the 2 strut assembly clevis bracket to steering knuckle attaching bolts. 7. Remove the 3 nuts attaching the strut assembly upper mount to the strut tower and remove the strut assembly from the vehicle. 8. To disassemble the strut assembly, Refer to STRUT DISASSEMBLY. DISASSEMBLY The strut assembly must be removed from the vehicle for it to be disassembled and assembled. For the disassembly and assembly of the strut assembly, use of Strut Spring Compressor, Pentastar Service Equipment (PSE) tool W-7200, or the equivalent, is recommended to compress the coil spring. Follow the manufacturer's instructions closely. WARNING: DO NOT REMOVE THE STRUT SHAFT NUT BEFORE THE COIL SPRING IS COMPRESSED. THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING SPRING TENSION FROM THE UPPER MOUNT AND PIVOT BEARING, BEFORE THE SHAFT NUT IS REMOVED. 1. Position the strut assembly in the strut coil spring compressor following the manufacturers instructions. Position the lower hooks on the coil spring first. The strut clevis bracket should be positioned straight outward from the compressor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber > Page 7072 2. Turn the upper mount of the strut assembly toward the inside of the compressor as shown to allow positioning of the compressor upper hooks. Position the upper hooks on top of the coil spring upper seat approximately 1 inch from outside diameter of seat. Do not allow hooks to be placed closer to edge. Place a clamp on the lower end of the coil spring, so the strut is held in place once the strut shaft nut is removed. 3. Compress the coil spring until all coil spring tension is removed from the upper mount. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber > Page 7073 4. Install Strut Nut Socket, Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, remove the nut from the strut shaft. 5. Remove the upper mount from the strut shaft. 6. If the pivot bearing needs to be serviced, remove it from the top of the coil spring upper seat by pulling it straight up. 7. Remove the clamp from the bottom of the coil spring and remove the strut out through the bottom of the coil spring. NOTE: If the coil spring or upper spring seat needs to be serviced, proceed with the next step, otherwise, proceed with step 10. 8. Release the tension from the coil spring by backing off the compressor drive fully. Push back the compressor upper hooks and remove the upper spring seat with upper spring isolator. 9. Remove the coil spring from the spring compressor. 10. Remove the dust shield and jounce bumper as an assembly from the strut shaft by pulling both straight up and off the strut shaft. The dust shield cannot be separated from the jounce bumper until after it is removed from strut shaft. 11. Remove the jounce bumper from the dust shield. The jounce bumper is removed from the dust shield by collapsing the dust shield until the jounce bumper can be pulled free from the dust boot. 12. Remove the spring isolator from the lower spring seat on the strut. 13. Inspect the strut assembly components for the following and replace as necessary: ^ Inspect the strut for any condition of shaft binding over the full stroke of the shaft. ^ Check the upper mount for cracks and distortion and its retaining studs for any sign of damage. ^ Check the upper seat for stress cracks and wear. ^ Check the upper spring isolator for severe deterioration. ^ Check for binding of the strut assembly pivot bearing. ^ Inspect the dust shield for rips and deterioration. ^ Inspect the jounce bumper for cracks and signs of deterioration. ASSEMBLY For the disassembly and assembly of the strut assembly, use of Strut Spring Compressor, Pentastar Service Equipment (PSE) tool W-7200, or the equivalent, is recommended to compress the coil spring. Follow the manufacturer's instructions closely. NOTE: Coil Springs on this vehicle are side-oriented. Springs on the left side of the vehicle have a left-hand wind top-to-bottom while springs on the right side have a right-hand wind top-to-bottom. Left and right springs must not be interchanged. NOTE: If the coil spring has been removed from the spring compressor, proceed with the next step, otherwise, proceed with step 5. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber > Page 7074 1. Place the coil spring in the compressor lower hooks following the manufacturers instructions. Proper orientation of the spring to the strut (once installed) is necessary. Consider the following when placing the coil spring in the compressor: From above, the compressor back is at the 12 o'clock position, and you, standing in the front of the machine, are at the 6 o'clock position. Place the lower coil spring end at the 6 o'clock position for both left and right springs. 2. Install the upper seat and upper isolator on top of the coil spring. Position the notch in the perimeter of the upper seat toward the front of the compressor (same 6 o'clock position as in step 1). 3. Position the upper hooks on top of the coil spring upper seat so the upper hooks span approximately 1 inch past outside diameter of upper seat. This will allow proper clearance for upper mount installation without pinching the hooks in-between the two pieces. Do not allow hooks to be placed closer to edge. 4. Compress the coil spring far enough to allow strut installation. 5. If the pivot bearing has been removed from the upper seat, install the pivot bearing on the top of the upper spring seat. The bearing must be installed on upper seat with the smaller diameter side of the pivot bearing toward the spring seat. Be sure the pivot bearing is sitting flat on the spring seat once mounted. 6. Install the spring isolator on the lower spring seat of the strut. 7. Install the jounce bumper on the strut shaft. The jounce bumper is to be installed with the small end pointing downward. 8. Install the dust shield on the strut. Collapse and stretch the dust shield down over the top of the jounce bumper until the dust shield snaps into the slot on the jounce bumper. The jounce bumper will be at the top of the inner dust boot. Return the dust shield to its fully extended length. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber > Page 7075 9. Install the strut through the bottom of the coil spring until the lower spring seat contacts the lower end of the coil spring. The clevis bracket on the strut should point straight outward away from the compressor (to the 6 o'clock position). This position should be within 5° of the lower end tip of the coil spring. If necessary, reposition the strut or coil spring in the compressor so both of these line up straight outward away from the compressor (to the 6 o'clock position). Install the clamp to hold the strut and coil together. 10. Install the strut mount over the strut shaft and onto the top of the pivot bearing and upper seat as shown. Loosely install the retaining nut on the strut shaft. 11. Install Strut Nut Socket (on the end of a torque wrench), Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, tighten the strut shaft retaining nut to a torque of 100 Nm (75 ft. lbs.). NOTE: Before releasing the tension the compressor has on the spring, using the following figure as reference, make sure the upper spring seat, coil spring and strut clevis bracket are all lined up properly (within 5° of one another). 12. Slowly release the tension from the coil spring by backing off the compressor drive fully. As the tension is relieved, make sure the upper mount, pivot bearing and upper seat are align properly. Remove the clamp from the lower end of the coil spring and strut. Push back the spring compressor upper and lower hooks, then remove the strut assembly from the spring compressor. 13. Install strut assembly on the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Shock Absorber > Page 7076 INSTALLATION CAUTION: Front strut coil springs are side-oriented. When installing a strut assembly, make sure the strut being installed has the correct coil spring for that side of the vehicle. Springs on the left side of the vehicle have a left-hand wind top-to-bottom while springs on the right side have a right-hand wind top-to-bottom. Do not interchange the two sides. 1. Install strut assembly into strut tower, aligning and installing the 3 studs on the upper strut mount into the holes in shock tower. Install the 3 upper strut mount attaching nut/washer assemblies. Then using a crow foot. tighten the 3 attaching nuts to a torque of 28 Nm (250 in. lbs.). CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be turned during installation. Install nuts while holding bolts stationary in the steering knuckles. NOTE: The strut clevis-to-steering knuckle bolts are installed differently on each side of the vehicle. Left hand side bolts are to be installed from vehicle rear to front. Right side bolts are to be installed from vehicle front to rear. 2. Align strut assembly with steering knuckle. Position arm of steering knuckle into strut assembly clevis bracket. Align the strut assembly clevis bracket mounting holes with the steering knuckle mounting holes. Install the 2 strut assembly to steering knuckle attaching bolts. If strut assembly is attached to steering knuckle using a cam bolt, the cam bolt must be installed in the lower slotted hole on strut clevis bracket. Tighten the strut clevis-to-steering knuckle attaching bolts to a torque of 81 Nm (60 ft. lbs.) plus an additional 1/4 (90°) turn after specified torque is met. 3. Install the stabilizer bar link mounting stud through the bracket on the strut assembly. CAUTION: When installing the nut on the mounting stud of the stabilizer bar link, do not allow the stud to rotate in it's socket. Hold the stud from rotating by placing an open-end wrench on the flat machined into the stud. 4. Hand thread the nut on the end of the stabilizer bar link stud. Hold the stud from turning by placing an open-end wrench on the flat machined into the link's mounting stud, then tighten the nut while holding the wrench in place. Tighten the nut to a torque of 88 Nm (65 ft. lbs.). 5. Install the hydraulic brake hose and speed sensor cable routing brackets on the strut assembly brackets. Tighten the routing bracket attaching bolts to a torque of 13 Nm (10 ft. lbs.). 6. Install the wheel/tire assembly on the vehicle. 7. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications Suspension Travel Bumper: Specifications Jounce Bumper Mounting Bolt ............................................................................................................ .................................................... 33 Nm (24 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications > Page 7080 Suspension Travel Bumper: Description and Operation DESCRIPTION There are two jounce bumpers used in the rear suspension. One mounts to each frame rail above the rear axle. OPERATION The jounce bumper limits suspension travel and metal-to-metal contact of the rear axle with the frame under full jounce conditions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications > Page 7081 Suspension Travel Bumper: Service and Repair REMOVAL 1. Remove the bolt attaching the jounce bumper to frame rail. 2. Remove the jounce bumper from the frame rail. INSTALLATION 1. Hook the forward end of the jounce bumper bracket in the mounting hole of the frame rail, then install the mounting bolt in the opposite end, securing the bumper to the frame rail. 2. Tighten the jounce bumper mounting bolt to 33 Nm (290 in. lbs.) torque. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Hub And Bearing Mounting Bolts Front .................................................................................................................................................... ................................................. 65 Nm (45 ft. lbs.) Rear ..................................................................... ............................................................................................................................... 129 Nm (95 ft. lbs.) Hub And Bearing Axle Hub Nut .......................................................................................................................................................... 244 Nm (180 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Description and Operation > Front Wheel Bearing: Description and Operation Front HUB AND BEARING DESCRIPTION The front wheel bearing and front wheel hub of this vehicle are a hub and bearing unit type assembly (Unit III). This unit combines the front wheel mounting hub (flange) and the front wheel bearing into a sealed one-piece unit. The hub and bearing is mounted to the center of the steering knuckle. It is retained by four mounting bolts accessible from the inboard side of the steering knuckle. The hub flange has five wheel mounting studs. The wheel mounting studs used to mount the tire and wheel to the vehicle are the only replaceable components of the hub and bearing assembly. Otherwise, the hub and bearing is serviced only as a complete assembly. OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the driveshaft, along with the tire and wheel. The five wheel mounting studs mount the tire and wheel, and brake rotor to the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Description and Operation > Front > Page 7087 Wheel Bearing: Description and Operation Rear HUB AND BEARING DESCRIPTION The rear wheel bearing and rear wheel hub of this vehicle are a one-piece sealed unit, or hub and bearing unit type assembly (Unit III). The hub and bearing is mounted to the center of the rear axle using 4 mounting bolts. It has five wheel mounting studs on the hub flange. All Wheel Drive vehicles have a hub and bearing unit with a splined hole in the center of the hub for rear driveshaft stub axle acceptance. Front Wheel Drive vehicles with antilock brakes have an internally mounted wheel speed sensor and tone wheel. This hub and bearing can be identified by the rounded cap and molded in connector on the rear of the assembly. The sensor and tone wheel cannot be serviced separately from the hub and bearing. OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the tire and wheel assembly (and driveshaft on All-Wheel-Drive vehicles). The five wheel mounting studs mount the tire and wheel assembly, and disc brake rotor or brake drum to the vehicle. On All Wheel Drive vehicles, the splined mating of the driveshaft stub axle and hub allows the driveshaft to rotate with the hub and wheel. Front Wheel Drive vehicles equipped with antilock brakes have a wheel speed sensor and tone wheel mounted to the rear of the hub and bearing. The tone wheel rotates with the hub which is sensed by the wheel speed sensor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front DIAGNOSIS AND TESTING - HUB AND BEARING The condition of the front hub and bearing assembly is diagnosed using the inspection and testing procedure. The bearing contained in the Unit III front hub/bearing assembly will produce noise and vibration when worn or damaged. The noise will generally change when the bearings are loaded. A road test of the vehicle is normally required to determine the location of a worn or damaged bearing. Find a smooth level road surface and bring the vehicle up to a constant speed. When vehicle is at a constant speed, swerve the vehicle back and forth from the left and to the right. This will load and unload the bearings and change the noise level. When bearing damage is slight, the noise is sometimes noticeable at lower speeds and at other times is more noticeable at speeds above 105 km/h (65 mph). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 7090 Wheel Bearing: Testing and Inspection Rear DIAGNOSIS AND TESTING - HUB AND BEARING The bearing contained in the hub and bearing assembly will produce noise and vibration when worn or damaged. The noise will generally change when the bearings are loaded. A road test of the vehicle is normally required to determine the location of a worn or damaged bearing. Find a smooth level road surface and bring the vehicle up to a constant speed. When vehicle is at a constant speed, swerve the vehicle back and forth from the left and to the right. This will load and unload the bearings and change the noise level. When bearing damage is slight, the noise is sometimes noticeable at lower speeds and at other times is more noticeable at speeds above 105 km/h (65 mph). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front REMOVAL NOTE: Replacement of the Unit III front hub/bearing assembly can be normally done without having to remove the steering knuckle from the vehicle. In the event that the hub/bearing is frozen in the steering knuckle and cannot be removed by hand, it will have to be pressed out of the steering knuckle. The steering knuckle will require removal from the vehicle to allow the hub/bearing assembly to be pressed out of the steering knuckle. 1. Raise vehicle. 2. Remove wheel lug nuts, and front tire and wheel assembly. 3. Remove the cotter pin, nut lock and spring washer from the stub axle. 4. With aid of a helper applying the brakes to keep the front hub from turning, remove the hub nut. 5. Remove disc brake caliper and adapter as an assembly from knuckle as shown. Hang assembly out of the way using a bungee cord or wire. Do not allow caliper hang by brake hose. 6. Remove brake rotor from hub and bearing. 7. Push in on end of driveshaft stub shaft, pushing its splines out of the hub splines. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 7093 8. Remove the four hub and bearing mounting bolts from the rear of steering knuckle. Use care not to come in contact with and damage the ABS tone wheel on the driveshaft stub shaft upon bolt removal. 9. Remove the hub and bearing assembly from the steering knuckle. INSTALLATION CAUTION: Hub and bearing assembly mounting surfaces on the steering knuckle and stub axle must be smooth and completely free of foreign material or nicks prior to installing hub and bearing assembly. CAUTION: When installing hub and bearing into steering knuckle, be careful not to damage the bearing seal on the outer C/V joint. 1. Install hub and bearing onto stub axle and into steering knuckle until squarely seated on the face of the steering knuckle. 2. Install the 4 hub and bearing mounting bolts from the rear of the knuckle. Equally tighten all 4 mounting bolts in a cries-cross pattern until hub/bearing assembly is squarely seated against front of steering knuckle. Tighten mounting bolts to a torque of 65 Nm (45 ft. lbs.) 3. Install the brake rotor on the hub and bearing. 4. Install brake caliper and adapter assembly back over brake rotor and align with mounting holes on steering knuckle. Install the mounting bolts and tighten to 169 Nm (125 ft. lbs.) torque. 5. Install the hub nut on the end of the stub axle. With aid of a helper applying the brakes to keep the front hub from turning, tighten the hub nut to Install the mounting bolts and tighten to 244 Nm (180 ft. lbs.) torque. 6. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 7. Lower vehicle to the ground. 8. Check the front wheel alignment toe setting and reset if not within specifications. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 7094 Wheel Bearing: Service and Repair Rear REMOVAL - FWD 1. Raise vehicle. 2. Remove wheel and tire. 3. Remove brake drum or disc brake caliper and rotor from hub and bearing. 4. If equipped with antilock brakes, perform the following: a. Remove secondary (yellow) retaining clip at rear of wheel speed sensor head. b. Push up on metal retaining clip until it bottoms. This will release wheel speed sensor head from hub and bearing. c. While holding metal clip up, pull back on wheel speed sensor head removing it from hub and bearing. 5. Remove the 4 bolts attaching the hub and bearing to the rear axle. CAUTION: Corrosion may occur between the hub and bearing, and the axle. If this occurs the hub and bearing will be difficult to remove from the axle. If the hub and bearing will not come out of the axle by pulling on it by hand, do not pound on the hub and bearing to remove it from the axle. Damage will occur. Use the following procedure. 6. If the hub and bearing cannot be removed from the axle by hand, use Remover, Special Tool 8458 and the following procedure to press the hub and bearing out of the axle. a. Remove the two outboard spring plate bolts. b. Thread Threaded Guide Pins into hub and bearing mounting bolt holes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 7095 c. Using the spring plate bolts, install the Screw Mount, Special Tool 8458-2, as shown. Mount the Screw Mount to the spring plate with the tool number facing the hub and bearing and the beveled edge on the bottom facing the spring, otherwise the Forcing Screw will rub the spring plate when installed. d. Place Push Plate, Special Tool 8458-1, on ends of Threaded Guide Pins e. Place a dab of grease in dimple of Push Plate. f. Install Forcing Screw, Special Tool 8458-3, through Screw Mount from rear. g. Tighten the Forcing Screw up against dimple in Push Plate and press hub and bearing out of axle by continuing to tighten screw. h. Remove the tool. i. Reinstall the two outboard spring plate bolts. Tighten the bolts to 102 Nm (75 ft. lbs.) torque. 7. Remove the hub/bearing from the rear axle and brake support plate. INSTALLATION - FWD 1. Install the 4 hub and bearing to axle mounting bolts into the holes in the flange of the rear axle. 2. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. 3. Align the rear hub and bearing with the 4 mounting bolts and start mounting bolts into hub and bearing. Tighten the 4 bolts in a crisscross pattern until the hub and bearing and brake support plate is fully and squarely seated onto flange of rear axle. Tighten the 4 mounting bolts to a torque of 129 Nm (95 ft. lbs.) NOTE: If equipped with antilock brakes, make sure wheel speed sensor stays clean and dry as it is installed into the hub and bearing cap. 4. If the vehicle is equipped with antilock brakes, perform the following: a. If metal sensor retaining clip is not in the neutral installed position on hub and bearing cap, install from the bottom, if necessary, and push clip upward until it snaps into position. b. Install wheel speed sensor head into rear of hub and bearing aligning index tab with the notch in the top of the mounting hole. Push the sensor in until it snaps into place on the metal retaining clip. c. Install secondary (yellow) retaining clip over wheel speed sensor head and engage the tabs on each side. 5. Install brake drum or disc brake rotor and brake caliper. 6. Install wheel and tire. Tighten the wheel nuts in the proper sequence to a torque of 135 Nm (100 ft. lbs.). 7. Adjust the rear brakes as necessary. 8. Lower vehicle. 9. Road test vehicle to ensure proper operation of brakes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub And Bearing Axle Hub Nut Front .................................................................................................................................................... ............................................. 244 Nm (180 ft. lbs.) Rear ..................................................................... ............................................................................................................................. 244 Nm (180 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The use of tire sealants is strictly prohibited for vehicles equipped with the Tire Pressure Monitoring system. Tire sealants can clog tire pressure sensors. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. CAUTION: Any time a sensor is to be installed in a wheel, a new seal and washer must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 7105 Tire Pressure Sensor: Description and Operation SENSOR - TPM DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor is mounted to each wheel in place of the traditional tire valve stem (Fig. 18). Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency (Fig. 18). The TPM sensors are designed for original style factory wheels. Do not attempt to install a tire pressure sensor in an aftermarket wheel. The serviceable components of the tire pressure sensor are (Fig. 19): Sensor-To-Wheel Seal and Metal Washer - Valve Stem Cap - Valve Stem Core - Valve Stem Nut Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 7106 The valve stem caps and cores used are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. OPERATION The battery operated tire pressure sensors lay dormant (Park Mode), then wake and start transmitting (Drive Mode) when the vehicle first reaches speeds over 15 mph (24 km/h). Once the wheels stop rotating for a period of approximately 20 minutes, the sensors shut down until again awaken. Although not transmitting as when in Drive Mode, while in Park Mode, the sensors still transmit approximately once every 13 hours to let the receiver know air pressure status at that time. Using an RF signal, each sensor transmits tire pressure data approximately once every minute. Each sensor's (transmitter) broadcast is uniquely coded so that the Sentry Key Remote Entry Module (SKREEM) can monitor the state of each of the sensors on the four rotating road wheels. The SKREEM automatically learns and stores the sensor's ID while driving after a sensor has been replaced. There is no formal retraining procedure necessary. For additional information, refer to appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 7107 Tire Pressure Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TIRE PRESSURE SENSOR NOTE: Tire pressure may increase from 2 to 6 psi (14 to 41 kPa) during normal driving conditions. Do NOT reduce this normal pressure build up. When diagnosing a tire pressure issue, always check air pressure in the tires first with a known accurate air gauge. Adjust air pressure as necessary to that listed on the Tire Inflation Pressure Label (Placard) provided with the vehicle (usually applied to the driver's side B-pillar). After adjusting air pressure in a tire, allow approximately two minutes for the message or indicator lamp to go out. Check the tire pressure indicator lamp in the instrument cluster. If the lamp is illuminating continuously, proceed as listed. If the indicator lamp is flashing on/off three times, once every ten minutes, there is a system fault detected. Refer to the appropriate diagnostic information. If air pressure in any tire is low, inspect all the tires for leaks. A water "dunk tank" or other water test may be used to check for a leak around the sensor as long as any water at the valve core is removed once the procedure is completed. The water can be easily expelled from the core area by pushing in on the core for several seconds, allowing escaping air to drive out any moisture. Reinflate the tire as necessary. Always make sure the original valve stem cap is securely installed to keep moisture out of the sensor. If the gauge-read pressure in the tires does not indicate a tire pressure issue, refer to the appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 7108 Tire Pressure Sensor: Service and Repair TIRE PRESSURE SENSOR REMOVAL 1. Remove tire and wheel assembly from vehicle. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 2. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor. That includes both front and rear beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool at the valve stem ± 10° (Fig. 20), then proceed to dismount the tire from the wheel. Use this process on both the upper and lower tire beads. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 7109 3. Remove sensor nut retaining sensor to wheel (Fig. 21). While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 4. Remove sensor from wheel (Fig. 21). INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal and metal washer at base of valve stem to ensure proper sealing (Fig. 22). 1. Wipe area clean around sensor/valve stem mounting hole in wheel. Make sure surface of wheel is not damaged. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 7110 CAUTION: To avoid damaging sensor antenna strap (Fig. 23), hold pressure against rear of metal valve stem (Fig. 24) while sensor is inserted through wheel mounting hole and nut is installed. 2. Insert sensor through wheel as shown keeping pressure against rear of metal valve stem. (Fig. 24). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) by hand (Fig. 24). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 7111 NOTE: Before tightening sensor nut, push downward on sensor housing in an attempt to make it flush with interior contour of wheel (Fig. 25). 4. While holding sensor in position, tighten sensor nut to 6.5 Nm (58 inch lbs.) torque. CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 inch lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function, however, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem approximately 210° from the head of the changer in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire (Fig. 26). Use this procedure on both the upper and lower tire beads. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions > Page 7112 b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem is approximately 210° from the head of the changer in a clockwise direction from the mounting end of the tool (Fig. 27) Make sure the sensor is clear of the lower bead breaker area to avoid damaging the sensor when the breaker rises (Fig. 27). Rotate the tool in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install wheel and tire assembly on vehicle. 8. Drive vehicle for a minimum of five minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time the system will learn the new sensor ID code and will clear any DTCs automatically. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Service and Repair Low Tire Pressure Indicator: Service and Repair Inspect all tire for proper inflation pressure, once proper tire pressure has been set the TPM system warning will reset automatically once the ignition switch has been turned ON. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The use of tire sealants is strictly prohibited for vehicles equipped with the Tire Pressure Monitoring system. Tire sealants can clog tire pressure sensors. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. CAUTION: Any time a sensor is to be installed in a wheel, a new seal and washer must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 7120 Tire Pressure Sensor: Description and Operation SENSOR - TPM DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor is mounted to each wheel in place of the traditional tire valve stem (Fig. 18). Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency (Fig. 18). The TPM sensors are designed for original style factory wheels. Do not attempt to install a tire pressure sensor in an aftermarket wheel. The serviceable components of the tire pressure sensor are (Fig. 19): Sensor-To-Wheel Seal and Metal Washer - Valve Stem Cap - Valve Stem Core - Valve Stem Nut Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 7121 The valve stem caps and cores used are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. OPERATION The battery operated tire pressure sensors lay dormant (Park Mode), then wake and start transmitting (Drive Mode) when the vehicle first reaches speeds over 15 mph (24 km/h). Once the wheels stop rotating for a period of approximately 20 minutes, the sensors shut down until again awaken. Although not transmitting as when in Drive Mode, while in Park Mode, the sensors still transmit approximately once every 13 hours to let the receiver know air pressure status at that time. Using an RF signal, each sensor transmits tire pressure data approximately once every minute. Each sensor's (transmitter) broadcast is uniquely coded so that the Sentry Key Remote Entry Module (SKREEM) can monitor the state of each of the sensors on the four rotating road wheels. The SKREEM automatically learns and stores the sensor's ID while driving after a sensor has been replaced. There is no formal retraining procedure necessary. For additional information, refer to appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 7122 Tire Pressure Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TIRE PRESSURE SENSOR NOTE: Tire pressure may increase from 2 to 6 psi (14 to 41 kPa) during normal driving conditions. Do NOT reduce this normal pressure build up. When diagnosing a tire pressure issue, always check air pressure in the tires first with a known accurate air gauge. Adjust air pressure as necessary to that listed on the Tire Inflation Pressure Label (Placard) provided with the vehicle (usually applied to the driver's side B-pillar). After adjusting air pressure in a tire, allow approximately two minutes for the message or indicator lamp to go out. Check the tire pressure indicator lamp in the instrument cluster. If the lamp is illuminating continuously, proceed as listed. If the indicator lamp is flashing on/off three times, once every ten minutes, there is a system fault detected. Refer to the appropriate diagnostic information. If air pressure in any tire is low, inspect all the tires for leaks. A water "dunk tank" or other water test may be used to check for a leak around the sensor as long as any water at the valve core is removed once the procedure is completed. The water can be easily expelled from the core area by pushing in on the core for several seconds, allowing escaping air to drive out any moisture. Reinflate the tire as necessary. Always make sure the original valve stem cap is securely installed to keep moisture out of the sensor. If the gauge-read pressure in the tires does not indicate a tire pressure issue, refer to the appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 7123 Tire Pressure Sensor: Service and Repair TIRE PRESSURE SENSOR REMOVAL 1. Remove tire and wheel assembly from vehicle. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 2. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor. That includes both front and rear beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool at the valve stem ± 10° (Fig. 20), then proceed to dismount the tire from the wheel. Use this process on both the upper and lower tire beads. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 7124 3. Remove sensor nut retaining sensor to wheel (Fig. 21). While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 4. Remove sensor from wheel (Fig. 21). INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal and metal washer at base of valve stem to ensure proper sealing (Fig. 22). 1. Wipe area clean around sensor/valve stem mounting hole in wheel. Make sure surface of wheel is not damaged. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 7125 CAUTION: To avoid damaging sensor antenna strap (Fig. 23), hold pressure against rear of metal valve stem (Fig. 24) while sensor is inserted through wheel mounting hole and nut is installed. 2. Insert sensor through wheel as shown keeping pressure against rear of metal valve stem. (Fig. 24). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) by hand (Fig. 24). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 7126 NOTE: Before tightening sensor nut, push downward on sensor housing in an attempt to make it flush with interior contour of wheel (Fig. 25). 4. While holding sensor in position, tighten sensor nut to 6.5 Nm (58 inch lbs.) torque. CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 inch lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function, however, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem approximately 210° from the head of the changer in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire (Fig. 26). Use this procedure on both the upper and lower tire beads. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 7127 b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem is approximately 210° from the head of the changer in a clockwise direction from the mounting end of the tool (Fig. 27) Make sure the sensor is clear of the lower bead breaker area to avoid damaging the sensor when the breaker rises (Fig. 27). Rotate the tool in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install wheel and tire assembly on vehicle. 8. Drive vehicle for a minimum of five minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time the system will learn the new sensor ID code and will clear any DTCs automatically. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation Tires: Description and Operation TIRES DESCRIPTION Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain, in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: Rapid acceleration - Severe application of brakes - High-speed driving - Taking turns at excessive speeds - Striking curbs and other obstacles - Operating vehicle with over or under inflated tire pressures Radial ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval. This will help to achieve a greater tread-life potential. TIRE IDENTIFICATION Tire type, size, load index and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the Tire Identification chart to decipher the code. For example purposes, the tire size P225/60 R 16 97 T is used in the chart. An All Season type tire will also have either M + S. M & S or M - S (indicating mud and snow traction) imprinted on the side wall. An Extra or Light Load marking "XL" or "LL" may also be listed on the sidewall. The absence of an "XL" or "LL" marking infers a standard load tire. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Page 7131 TIRE IDENTIFICATION NOTE: Consult the tire manufacturer regarding any questions on tire specifications or capabilities. TIRE CHAINS Refer to the owners manual supplied with the vehicle to determine whether the use of tire chains is permitted on this vehicle. DESCRIPTION - RADIAL-PLY TIRES Radial-ply tires improve handling, tread life, ride quality and decrease rolling resistance. Radial-ply tires must always be used in sets of four and under no circumstances should they be used on the front only. It is recommended that tires from different manufacturers NOT be mixed. They may be mixed with a temporary spare tire when necessary. A maximum speed of 80 km/h (50 mph) is recommended while a temporary spare is in use. Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the same recommended inflation pressures. DESCRIPTION - REPLACEMENT TIRES WARNING: FAILURE TO EQUIP THE VEHICLE WITH TIRES HAVING ADEQUATE SPEED CAPABILITY CAN RESULT IN SUDDEN TIRE FAILURE. WARNING: IN ORDER TO MAINTAIN THE SPEED CAPABILITY OF THE VEHICLE, REPLACEMENT TIRES MUST HAVE SPEED RATINGS EQUAL TO OR HIGHER THAN THOSE FITTED TO THE VEHICLE AS ORIGINAL EQUIPMENT. IF TIRES WITH LOWER SPEED RATINGS ARE FITTED, THE VEHICLE'S HANDLING MAY BE AFFECTED AND THE SPEED CAPABILITY OF THE VEHICLE MAY BE LOWERED TO THE MAXIMUM SPEED CAPABILITY OF THE REPLACEMENT TIRES. TO AVOID AN ACCIDENT RESULTING IN SEVERE OR FATAL INJURY, CONSULT THE TIRE MANUFACTURER IN REGARDS TO MAXIMUM SPEED RATINGS. It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The original equipment tires provide a proper combination of many characteristics such as: Ride - Noise - Handling - Durability - Tread life - Traction - Rolling resistance - Speed capability The use of tires smaller than the minimum tire size approved for the vehicle can result in tire overloading and failure. Use tires that have the approved load rating for the vehicle and never overload them. Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure and loss of vehicle control. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Page 7132 The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. DESCRIPTION - SPARE TIRE (TEMPORARY) The temporary (convenience) spare tire is designed for emergency use only. The original tire should be repaired and reinstalled, or replaced with a new, at the first opportunity. The temporary (convenience) spare tire should be inflated to the pressure listed on its sidewall. Do not exceed speeds of 80 km/h (50 mph) when the temporary spare tire is in use on the vehicle. Refer to the Owner's Manual for more details. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tire Wear Patterns Tires: Testing and Inspection Tire Wear Patterns TIRE WEAR PATTERNS Under inflation will cause wear on the shoulders of tire. Over inflation will cause wear at the center of tire. Excessive camber causes the tire to run at an angle to the road. One side of tread is then worn more than the other (Fig. 29). Excessive toe-in or toe-out causes wear on the tread edges and a feathered effect across the tread (Fig. 29). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tire Wear Patterns > Page 7135 Tires: Testing and Inspection Tire/Vehicle Lead TIRE/VEHICLE LEAD Use the following Vehicle Lead Diagnosis And Correction Chart to diagnose and correct a vehicle lead or drift problem. VEHICLE LEAD DIAGNOSIS AND CORRECTION CHART Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Tire Wear Patterns > Page 7136 Tires: Testing and Inspection Tread Wear Indicators TREAD WEAR INDICATORS Tread wear indicators are molded into the bottom of the tread grooves. When tread depth is 1.6 mm (1/16 inch), the tread wear indicators will appear as a 13 mm (1/2 inch) band (Fig. 30). Tire replacement is necessary when indicators appear in two or more grooves or if localized balding occurs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures Tires: Procedures Cleaning CLEANING - TIRES Before delivery of a vehicle, remove the protective coating on the tires with white sidewalls or raised white letters. To remove the protective coating, apply warm water and let it soak for a few minutes. Afterwards, scrub the coating away with a soft bristle brush. Steam cleaning may also be used to remove the coating. CAUTION: DO NOT use gasoline, mineral oil, oil-based solvent or a wire brush for cleaning. Tire Inflation Pressures STANDARD PROCEDURE - TIRE INFLATION PRESSURES The specified tire pressures have been chosen to provide safe operation, vehicle stability, and a smooth ride. The proper tire pressure specification can be found on the Tire Inflation Pressure Label provided with the vehicle (usually on the driver's side B-pillar). A quality air pressure gauge is recommended to check tire air pressure. Tire pressure should be checked cold once per month. Check tire pressure more frequently when the weather temperature varies widely. Tire pressure will decrease when the outdoor temperature drops. After checking the air pressure, replace valve cap finger tight. Inflation pressures specified on the Tire Inflation Pressure Label are always the cold inflation pressure of the tire. Cold inflation pressure is obtained after the vehicle has not been operated for at least 3 hours, or the vehicle is driven less than one mile after being inoperative for 3 hours. Tire inflation pressures may increase from 2 to 6 pounds per square inch (psi) (14 to 41 kPa) during operation. Do not reduce this normal pressure buildup. Improper inflation can cause: Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride - The vehicle to drift. WARNING: OVER OR UNDER INFLATED TIRES CAN AFFECT VEHICLE HANDLING. THE TIRE CAN FAIL SUDDENLY, RESULTING IN LOSS OF VEHICLE CONTROL. Under inflation causes rapid shoulder wear, tire flexing, and can result in tire failure (Fig. 31). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 7139 Over inflation causes rapid center wear and loss of the tire's ability to cushion shocks (Fig. 32). Tire Pressure For High Speed Operation STANDARD PROCEDURE - TIRE PRESSURE FOR HIGH SPEED OPERATION DaimlerChrysler Corporation advocates driving at safe speeds within posted speed limits. Where speed limits allow the vehicle to be driven at high speeds, correct tire inflation pressure is very important. Vehicles loaded to maximum capacity should not be driven at continuous speeds over 120 km/h (75 mph). Never exceed the maximum speed capacity of the tire. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 7140 Tires: Removal and Replacement STANDARD PROCEDURE - TIRE LEAK REPAIRING For proper repairing, a radial tire must be removed from the wheel. Repairs should only be made if the defect, or puncture, is in the tread area (Fig. 33). The tire should be replaced if the puncture is located in the sidewall. Deflate tire completely before attempting to dismount the tire from the wheel. Use a lubricant such as a mild soap solution when dismounting or mounting tire. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary. Install wheel on vehicle, and progressively tighten the 5 wheel nuts to a torque of 135 Nm (100 ft. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels Wheels: Technical Service Bulletins Wheels - Caring for Chrome Wheels NUMBER: 22-001-05 GROUP: Wheels and Tires DATE: December 1, 2005 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-004-03, DATED SEPTEMBER 26, 2003 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND MODEL YEARS AND CLEANER SUGGESTIONS. SUBJECT: Chrome Wheel Care MODELS: 2000 - 2003 (AB) Ram Van/Wagon 2002 - 2004 (AN) Dakota 2000 - 2001 (BR/BE) Ram Truck 2004 - **2006** (CS) Pacifica 2002 - 2003 (DN) Durango 2002 - **2006 (DR/DH) Ram Truck** 2004 - **2006** (HB) Durango 2001 - **2006** (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2003 - **2006** (KJ) Liberty 1998 - 2004 (LH) Concorde/Intrepid/LHS/300M 2005 - **2006 (LX/LE) 300/Charger/Magnum** **2005 - 2006 (ND) Dakota** 1998 - 2000 (NS) Town & Country 2002 - **2005** (PL) Neon 1999 - 2002 (PR) Prowler 2001 - **2006** (PT) PT Cruiser 2001 - **2006** (RS) Town & Country/Caravan 2001 - **2005** (ST) Sebring/Stratus Coupe 2002 - **2006** (TJ) Wrangler **2002 - 2006 (VA) Sprinter** 2001 - 2004 (WJ) Grand Cherokee **2005 - 2006 (WK/WH) Grand Cherokee** **2006 (XK) Commander** 2003 - **2006 (ZB) Viper/Viper Coupe** Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels - Caring for Chrome Wheels > Page 7145 2004 - **2006 (ZH) Crossfire/Crossfire Convertible/SRT6** DISCUSSION: Chrome wheels should be cleaned regularly with **good quality car wash such as MOPAR Car Wash Concentrate p/n 04796236AB,** and water to maintain their luster and prevent corrosion. Wash them with the same soap solution as the body of the vehicle. Care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to wheels. MOPAR Tire and Wheel Cleaner, p/n 05066247AB - 22 oz. or 05066248AB - 5 gal. **or MOPAR Wheel Cleaner, p/n 04796239AB,** is recommended to remove normal brake dust, dirt, grease and grime. NOTE: To clean extremely dirty wheels, MOPAR Chrome Cleaner, pin 04318013, is recommended. Any of the "DO NOT USE" items listed below can damage or stain wheels and wheel trim. DO NOT USE: ^ Wheel cleaners that contain hydroflouric acid, biflouride compounds, sulfuric acid, or phosphoric acid. ^ Any abrasive type cleaner ^ Any abrasive cleaning pad (such as steel wool) or abrasive brush ^ Any oven cleaner. ^ A car wash that has carbide tipped wheel-cleaning brushes. CAUTION: Many commercial wheel cleaners contain acids that may harm the wheel surface. Avoid all "wheel acid" type cleaners. CAUTION: Any facility found using acid based wheel cleaners will void all wheel warranties, and all damage to customer wheels will be the facility's responsibility. Refer to Global Warranty Bulletin D-01-22 for further information. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7146 Wheels: Specifications Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7147 Wheels: Description and Operation WHEELS Original equipment wheels are designed for proper operation at all loads up to the specified maximum vehicle capacity. All models use either steel or aluminum drop-center wheels. Every wheel has raised sections between the rim flanges and rim drop well called safety humps (Fig. 34). Initial inflation of the tires forces the bead over these raised sections. In case of air loss, the safety humps hold the tire in position on the wheel until the vehicle can be brought to a safe stop. Cast aluminum wheels require special balance weights to fit on the flange of the rim (Fig. 35). When wheel alignment is necessary on a vehicle with cast aluminum wheels, special wheel clamps are required to avoid damage to the wheel's finish. The wheel studs and nuts are designed for specific wheel applications and must be replaced with equivalent parts. All aluminum wheels have wheel mounting (lug) nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7148 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: - Excessive runout - Dents, cracks or irregular bends - Damaged wheel stud (lug) holes - Air Leaks NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged, an original equipment replacement wheel should be used. When obtaining replacement wheels, they must be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. WARNING: Replacement with used wheels is not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. WARNING: DaimlerChrysler Corporation does not recommend that customers use "reconditioned" wheels (wheels that have been damaged and repaired) because they can result in a sudden catastrophic wheel failure which could cause loss of control and result in injury or death. For clarification: - Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is no exposure to paint curing heat over 200 degrees Fahrenheit. - Damaged wheels are those which have been bent, broken, cracked or sustained some other physical damage which may have compromised the wheel structure. - Repaired indicates that the wheel has been modified through bending, welding, heating, straightening, or material removal to rectify damage. - Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of original equipment painted or polished wheels, as this may alter mechanical properties and affect fatigue life. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7149 Wheels: Service and Repair WHEEL AND WHEEL TRIM CARE All wheels and wheel trim, especially aluminum and chrome plated, should be cleaned regularly using mild soap and water to maintain their luster and to prevent corrosion. Wash them with the same soap solution recommended for the body of the vehicle. When cleaning extremely dirty wheels, care must be taken in the selection of tire and wheel cleaning chemicals and equipment to prevent damage to the wheels. Mopar Wheel Treatment or Mopar Chrome Cleaner is recommended. Any of the "DO NOT USE" items listed below can damage wheels and wheel trim. DO NOT USE: Any abrasive cleaner - Any abrasive cleaning pad (such as steel wool) or abrasive brush - Any cleaner that contains an acid which can react with and discolor the chrome surface. Many wheel cleaners contain acids that can harm the wheel surface. - Oven cleaner - A car wash that uses carbide-tipped wheel cleaning brushes or acidic solutions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Hub And Bearing Mounting Bolts Front .................................................................................................................................................... ................................................. 65 Nm (45 ft. lbs.) Rear ..................................................................... ............................................................................................................................... 129 Nm (95 ft. lbs.) Hub And Bearing Axle Hub Nut .......................................................................................................................................................... 244 Nm (180 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front Wheel Bearing: Description and Operation Front HUB AND BEARING DESCRIPTION The front wheel bearing and front wheel hub of this vehicle are a hub and bearing unit type assembly (Unit III). This unit combines the front wheel mounting hub (flange) and the front wheel bearing into a sealed one-piece unit. The hub and bearing is mounted to the center of the steering knuckle. It is retained by four mounting bolts accessible from the inboard side of the steering knuckle. The hub flange has five wheel mounting studs. The wheel mounting studs used to mount the tire and wheel to the vehicle are the only replaceable components of the hub and bearing assembly. Otherwise, the hub and bearing is serviced only as a complete assembly. OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the driveshaft, along with the tire and wheel. The five wheel mounting studs mount the tire and wheel, and brake rotor to the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Description and Operation > Front > Page 7155 Wheel Bearing: Description and Operation Rear HUB AND BEARING DESCRIPTION The rear wheel bearing and rear wheel hub of this vehicle are a one-piece sealed unit, or hub and bearing unit type assembly (Unit III). The hub and bearing is mounted to the center of the rear axle using 4 mounting bolts. It has five wheel mounting studs on the hub flange. All Wheel Drive vehicles have a hub and bearing unit with a splined hole in the center of the hub for rear driveshaft stub axle acceptance. Front Wheel Drive vehicles with antilock brakes have an internally mounted wheel speed sensor and tone wheel. This hub and bearing can be identified by the rounded cap and molded in connector on the rear of the assembly. The sensor and tone wheel cannot be serviced separately from the hub and bearing. OPERATION The hub and bearing has internal bearings that allow the hub to rotate with the tire and wheel assembly (and driveshaft on All-Wheel-Drive vehicles). The five wheel mounting studs mount the tire and wheel assembly, and disc brake rotor or brake drum to the vehicle. On All Wheel Drive vehicles, the splined mating of the driveshaft stub axle and hub allows the driveshaft to rotate with the hub and wheel. Front Wheel Drive vehicles equipped with antilock brakes have a wheel speed sensor and tone wheel mounted to the rear of the hub and bearing. The tone wheel rotates with the hub which is sensed by the wheel speed sensor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front Wheel Bearing: Testing and Inspection Front DIAGNOSIS AND TESTING - HUB AND BEARING The condition of the front hub and bearing assembly is diagnosed using the inspection and testing procedure. The bearing contained in the Unit III front hub/bearing assembly will produce noise and vibration when worn or damaged. The noise will generally change when the bearings are loaded. A road test of the vehicle is normally required to determine the location of a worn or damaged bearing. Find a smooth level road surface and bring the vehicle up to a constant speed. When vehicle is at a constant speed, swerve the vehicle back and forth from the left and to the right. This will load and unload the bearings and change the noise level. When bearing damage is slight, the noise is sometimes noticeable at lower speeds and at other times is more noticeable at speeds above 105 km/h (65 mph). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Testing and Inspection > Front > Page 7158 Wheel Bearing: Testing and Inspection Rear DIAGNOSIS AND TESTING - HUB AND BEARING The bearing contained in the hub and bearing assembly will produce noise and vibration when worn or damaged. The noise will generally change when the bearings are loaded. A road test of the vehicle is normally required to determine the location of a worn or damaged bearing. Find a smooth level road surface and bring the vehicle up to a constant speed. When vehicle is at a constant speed, swerve the vehicle back and forth from the left and to the right. This will load and unload the bearings and change the noise level. When bearing damage is slight, the noise is sometimes noticeable at lower speeds and at other times is more noticeable at speeds above 105 km/h (65 mph). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front REMOVAL NOTE: Replacement of the Unit III front hub/bearing assembly can be normally done without having to remove the steering knuckle from the vehicle. In the event that the hub/bearing is frozen in the steering knuckle and cannot be removed by hand, it will have to be pressed out of the steering knuckle. The steering knuckle will require removal from the vehicle to allow the hub/bearing assembly to be pressed out of the steering knuckle. 1. Raise vehicle. 2. Remove wheel lug nuts, and front tire and wheel assembly. 3. Remove the cotter pin, nut lock and spring washer from the stub axle. 4. With aid of a helper applying the brakes to keep the front hub from turning, remove the hub nut. 5. Remove disc brake caliper and adapter as an assembly from knuckle as shown. Hang assembly out of the way using a bungee cord or wire. Do not allow caliper hang by brake hose. 6. Remove brake rotor from hub and bearing. 7. Push in on end of driveshaft stub shaft, pushing its splines out of the hub splines. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7161 8. Remove the four hub and bearing mounting bolts from the rear of steering knuckle. Use care not to come in contact with and damage the ABS tone wheel on the driveshaft stub shaft upon bolt removal. 9. Remove the hub and bearing assembly from the steering knuckle. INSTALLATION CAUTION: Hub and bearing assembly mounting surfaces on the steering knuckle and stub axle must be smooth and completely free of foreign material or nicks prior to installing hub and bearing assembly. CAUTION: When installing hub and bearing into steering knuckle, be careful not to damage the bearing seal on the outer C/V joint. 1. Install hub and bearing onto stub axle and into steering knuckle until squarely seated on the face of the steering knuckle. 2. Install the 4 hub and bearing mounting bolts from the rear of the knuckle. Equally tighten all 4 mounting bolts in a cries-cross pattern until hub/bearing assembly is squarely seated against front of steering knuckle. Tighten mounting bolts to a torque of 65 Nm (45 ft. lbs.) 3. Install the brake rotor on the hub and bearing. 4. Install brake caliper and adapter assembly back over brake rotor and align with mounting holes on steering knuckle. Install the mounting bolts and tighten to 169 Nm (125 ft. lbs.) torque. 5. Install the hub nut on the end of the stub axle. With aid of a helper applying the brakes to keep the front hub from turning, tighten the hub nut to Install the mounting bolts and tighten to 244 Nm (180 ft. lbs.) torque. 6. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 7. Lower vehicle to the ground. 8. Check the front wheel alignment toe setting and reset if not within specifications. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7162 Wheel Bearing: Service and Repair Rear REMOVAL - FWD 1. Raise vehicle. 2. Remove wheel and tire. 3. Remove brake drum or disc brake caliper and rotor from hub and bearing. 4. If equipped with antilock brakes, perform the following: a. Remove secondary (yellow) retaining clip at rear of wheel speed sensor head. b. Push up on metal retaining clip until it bottoms. This will release wheel speed sensor head from hub and bearing. c. While holding metal clip up, pull back on wheel speed sensor head removing it from hub and bearing. 5. Remove the 4 bolts attaching the hub and bearing to the rear axle. CAUTION: Corrosion may occur between the hub and bearing, and the axle. If this occurs the hub and bearing will be difficult to remove from the axle. If the hub and bearing will not come out of the axle by pulling on it by hand, do not pound on the hub and bearing to remove it from the axle. Damage will occur. Use the following procedure. 6. If the hub and bearing cannot be removed from the axle by hand, use Remover, Special Tool 8458 and the following procedure to press the hub and bearing out of the axle. a. Remove the two outboard spring plate bolts. b. Thread Threaded Guide Pins into hub and bearing mounting bolt holes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7163 c. Using the spring plate bolts, install the Screw Mount, Special Tool 8458-2, as shown. Mount the Screw Mount to the spring plate with the tool number facing the hub and bearing and the beveled edge on the bottom facing the spring, otherwise the Forcing Screw will rub the spring plate when installed. d. Place Push Plate, Special Tool 8458-1, on ends of Threaded Guide Pins e. Place a dab of grease in dimple of Push Plate. f. Install Forcing Screw, Special Tool 8458-3, through Screw Mount from rear. g. Tighten the Forcing Screw up against dimple in Push Plate and press hub and bearing out of axle by continuing to tighten screw. h. Remove the tool. i. Reinstall the two outboard spring plate bolts. Tighten the bolts to 102 Nm (75 ft. lbs.) torque. 7. Remove the hub/bearing from the rear axle and brake support plate. INSTALLATION - FWD 1. Install the 4 hub and bearing to axle mounting bolts into the holes in the flange of the rear axle. 2. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. 3. Align the rear hub and bearing with the 4 mounting bolts and start mounting bolts into hub and bearing. Tighten the 4 bolts in a crisscross pattern until the hub and bearing and brake support plate is fully and squarely seated onto flange of rear axle. Tighten the 4 mounting bolts to a torque of 129 Nm (95 ft. lbs.) NOTE: If equipped with antilock brakes, make sure wheel speed sensor stays clean and dry as it is installed into the hub and bearing cap. 4. If the vehicle is equipped with antilock brakes, perform the following: a. If metal sensor retaining clip is not in the neutral installed position on hub and bearing cap, install from the bottom, if necessary, and push clip upward until it snaps into position. b. Install wheel speed sensor head into rear of hub and bearing aligning index tab with the notch in the top of the mounting hole. Push the sensor in until it snaps into place on the metal retaining clip. c. Install secondary (yellow) retaining clip over wheel speed sensor head and engage the tabs on each side. 5. Install brake drum or disc brake rotor and brake caliper. 6. Install wheel and tire. Tighten the wheel nuts in the proper sequence to a torque of 135 Nm (100 ft. lbs.). 7. Adjust the rear brakes as necessary. 8. Lower vehicle. 9. Road test vehicle to ensure proper operation of brakes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Description and Operation Wheel Cover: Description and Operation WHEEL COVER This vehicle uses a bolt-on type wheel cover (Fig. 36). This bolt-on wheel cover cannot be removed from the wheel until three of the five wheel mounting nuts shown are removed (Fig. 36). The bolt-on wheel cover can then be removed with the remaining two wheel nuts tightened in place. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Description and Operation > Page 7167 Wheel Cover: Service and Repair WHEEL COVER REMOVAL 1. Noting the location of the valve stem in relationship to the wheel mounting nuts, remove the three wheel mounting nuts securing the wheel cover to the wheel and hub (Fig. 36). CAUTION: When removing the wheel cover, do not pry the wheel cover from the wheel. This can result in damage to the wheel cover. The wheel cover is removed by pulling it off the wheel by hand. 2. Grasp the wheel cover at the edges in line with the remaining installed wheel nuts and pull straight outward from the wheel. This will pop the wheel cover retaining tabs over the two remaining wheel nuts, removing the wheel cover from the wheel. INSTALLATION NOTE: Wheel mounting nuts must be installed on the studs as shown to allow installation of the wheel cover (Fig. 37). 1. Place the wheel cover on the wheel in the following fashion: a. Align the valve notch in the wheel cover with the valve stem on the wheel. b. At the same time, align the two holes in the wheel cover having the retaining tabs with the two installed wheel nuts (Fig. 38). c. Press in on center of wheel cover until wheel cover retaining tabs push past and engage rear of previously installed wheel mounting nuts (Fig. 38). This will hold the wheel cover in place. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Cover > Component Information > Description and Operation > Page 7168 2. Install and lightly tighten the three remaining wheel mounting nuts, securing the wheel cover in place (Fig. 36). 3. Tighten all five wheel mounting nuts in the proper sequence (Fig. 39). Tighten wheel nuts to a torque of 135 Nm (100 ft. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Hub And Bearing Axle Hub Nut Front .................................................................................................................................................... ............................................. 244 Nm (180 ft. lbs.) Rear ..................................................................... ............................................................................................................................. 244 Nm (180 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Mounting (Lug) Nut ................................................................................................................... ............................................... 135 Nm (100 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front WHEEL MOUNTING STUDS FRONT REMOVAL CAUTION: Wheel mounting studs MUST NOT be hammered out of hub flange of hub and bearing assembly. If a stud is removed by hammering it out, damage to hub and bearing assembly will occur leading to premature bearing failure. 1. Raise vehicle. 2. Remove front wheel and tire assembly. 3. Remove two adapter mounting bolts securing disc brake caliper adapter to steering knuckle (Fig. 40). 4. Remove disc brake caliper and adapter as assembly from steering knuckle (Fig. 40). Hang assembly out of way using wire or a bungle cord. Use care not to overextend brake hose when doing this. 5. Remove brake rotor from hub by pulling it straight off wheel mounting studs (Fig. 40). 6. On wheel mounting stud to be removed, install a wheel mounting (lug) nut far enough so the threads on the stud are even with end of nut. Install Remover, Special Tool C-4150A, on hub and bearing flange and wheel stud (Fig. 41). 7. Tighten down on Remover, pushing wheel stud out of hub flange. Once shoulder of wheel stud is past flange, remove special tool. Remove nut Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7178 from stud and remove stud from hub flange. INSTALLATION 1. Install replacement wheel stud into flange of hub and bearing from rear. Install washers on wheel stud, then install a standard type wheel mounting (lug) nut on stud with flat side of lug nut against washers as shown (Fig. 42). 2. Tighten nut, pulling wheel stud into hub flange. Once head of stud is fully seated against rear of hub flange, remove nut and washers from stud. 3. Install brake rotor back on hub and bearing (Fig. 40). 4. Install brake caliper and adapter back over brake rotor aligning adapter with mounting holes on steering knuckle (Fig. 40). 5. Install two adapter mounting bolts securing adapter to steering knuckle. Tighten mounting bolts to 169 Nm (125 ft. lbs.)torque. 6. Install wheel and tire assembly. Tighten wheel mounting (lug) nuts in proper sequence to 135 Nm (100 ft. lbs.) torque. 7. Lower vehicle. 8. Road test vehicle to ensure proper operation of the brakes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7179 Wheel Fastener: Service and Repair Wheel Mounting Studs - Rear Removal REMOVAL CAUTION: If a wheel stud needs to be replaced in the hub and bearing assembly, the studs MUST NOT be hammered out of the hub flange. If a wheel stud is removed by hammering it out of the hub flange, damage to the hub and bearing assembly will occur leading to premature hub and bearing failure. NOTE: Use one of the following procedures to remove one of five studs on a hub and bearing flange. DISC BRAKES 1. Raise and support the vehicle. 2. Remove the rear wheel and tire assembly. 3. Remove the disc brake caliper to adapter guide pin bolts (Figure 1). Figure 1 Caliper Guide Pin Bolts 4. Remove the rear brake caliper from the adapter using the following procedure (Figure 2): a. Rotate the front of the caliper up from the adapter. b. Pull the rear of the caliper and the outboard brake shoe anti-rattle clip out from under the rear abutment on the brake adapter. c. Lift the caliper from the rotor and support it using a bungee cord or wire attached to the underbody of the vehicle. DO NOT allow the caliper to hang by the flex hose. Damage can result. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7180 Figure 2 Removing/Installing Caliper 5. Remove any brake rotor retainer clips, then remove the brake rotor by pulling it straight off the wheel studs. 6. Remove the hold-down spring and pin from the trailing parking brake shoe (Figure 3). Figure 3 Parking Brake Adjuster And Springs Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7181 7. Shorten (back off) the adjuster screw (Figure 3) to minimum length, then spread the leading and trailing parking brake shoes apart and remove the adjuster. 8. Remove the lower return spring from the leading and trailing parking brake shoes (Figure 3). 9. Pull the bottom of the trailing parking brake shoe rearward and retain it on the backing plate flange of the brake adapter (Figure 4). Figure 4 Puller C-4150A On Wheel Stud 10. Install Remover, Special Tool C-4150A, on the hub and bearing flange and wheel stud (Figure 4). 11. Tighten the Remover, pushing the wheel mounting stud out the rear of the hub and bearing flange. When the shoulder of the stud is past the flange, remove the Remover. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7182 Figure 5 Stud Removal/Installation 12. Rotate the hub and bearing flange around until the stud lines up with the pocket in the brake adapter, then remove the stud from the hub and bearing flange utilizing the extra clearance that pocket allows (Figure 5). DRUM BRAKES 1. Raise and support the vehicle. 2. Remove the rear wheel and tire assembly. See: Service and Repair 3. Remove the brake drum. 4. If possible, install a wheel mounting nut on the wheel stud to be removed so the threads on wheel stud are even with end of lug nut (Figure 6). Figure 6 Wheel Stud Removal From Hub And Bearing Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7183 5. Install Remover, Special Tool C-4150A, on the hub and bearing flange and wheel stud (Figure 6). 6. Tighten the Remover, pushing the wheel stud out the rear of the hub and bearing flange. When the shoulder of the wheel stud is past the flange, remove the Remover. 7. Remove the wheel stud from the hub and bearing flange. Installation INSTALLATION NOTE: Use one of the following procedures to install one of five studs on a hub and bearing flange. DISC BRAKES 1. Rotate the hub and bearing flange around until the stud mounting hole lines up with the pocket in the brake adapter. 2. Insert the NEW wheel stud into the hub and bearing flange from the rear utilizing the pocket in the brake adapter (Figure 4). 3. Install several washers and a standard wheel mounting (lug) nut on the wheel stud (Figure 1). Install the nut so that the flat side of the nut is against the washers to eliminate any binding. Figure 1 Wheel Mounting Stud Installation 4. Tighten the wheel mounting nut (Figure 1) pulling the wheel stud into the hub flange. When the head of the stud is fully seated against the rear of the hub flange, remove the nut and washers. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7184 5. Place the trailing parking brake shoe back into mounted position. 6. Install the lower return spring between the leading and trailing parking brake shoes (Figure 3). When installing the lower return spring, be sure to install it behind the parking brake shoes as shown. 7. Install the adjuster between the leading and trailing parking brake shoes (Figure 3). 8. Install the hold-down spring and pin through the trailing parking brake shoe (Figure 3). 9. Adjust the parking brake shoes. 10. Install the brake rotor on the hub and bearing. CAUTION: Use care when installing the brake caliper assembly onto the adapter, so the caliper guide pin bushings do not get damaged by the mounting bosses on the adapter. 11. Carefully lower the brake caliper with brake shoes over the brake rotor and onto the adapter using the reverse order of how it was removed (Figure 2). CAUTION: When installing the guide pin bolts, extreme caution should be taken not to cross-thread the caliper guide pin bolts. 12. Install the caliper guide pin bolts. Tighten the guide pin bolts to 35 Nm (26 ft. lbs.). 13. Install wheel and tire assembly on vehicle. Tighten the wheel mounting (lug) nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 14. Check operation of the parking brakes. 15. Lower the vehicle. DRUM BRAKES 1. Install the NEW wheel stud into the flange of the hub and bearing assembly. 2. Install several washers on the wheel stud (Figure 1), then install a wheel mounting (lug) nut on the stud with the flat side of the lug nut against the washers to eliminate any binding. 3. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing assembly. When the head of the stud is fully seated against the flange, remove the nut and washers. 4. Install the brake drum and adjust the brake shoes as necessary. 5. Install wheel and tire assembly on vehicle. Tighten the wheel mounting (lug) nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.). 6. Lower the vehicle. Figure 2 Removing/Installing Caliper Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7185 Figure 3 Parking Brake Adjuster And Springs Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 7186 Figure 4 Stud Removal/Installation Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations Air Door Actuator / Motor: Component Locations Actuators - Front, LHD Actuators - Front, LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 7193 Actuator - Front, RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 7194 Actuator - Front, RHD Actuators - Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 7195 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 7196 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 7197 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Component Locations > Page 7198 Right Quarter Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 7199 Air Door Actuator / Motor: Diagrams Driver Blend Door Actuator Mode Door Actuator Passenger Blend Door Actuator Rear Temperature Motor (3 Zone ATC) Rear Mode Motor (3 Zone ATC) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Page 7200 Recirculation Door Actuator Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator Air Door Actuator / Motor: Description and Operation Blend Door Actuator Front Blend Door Actuator The blend door actuators for the front heating-A/C system are reversible, 12-volt Direct Current (DC), servo motors. Models with the front single zone heating-A/C system have a single blend-air door, which is controlled by a single blend door actuator. Models with the optional front dual zone heating-A/C system have dual blend-air doors, which are controlled by two blend door actuators. The blend door actuator for the single zone heating-A/C system is located on the driver side end of the front HVAC air distribution housing, close to the middle of the distribution housing. For the dual zone heating-A/C system, the same blend door actuator used for the single zone system becomes the driver side blend door actuator, which is mechanically connected to only the driver side blend-air door. A second separate blend door actuator is also located on the driver side of the front HVAC air distribution housing which is mechanically connected to only the passenger side blend-air door. The front blend door actuators are interchangeable with each other, as well as with the actuators for the mode-air door and the recirculation-air door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Each actuator also has an identical output shaft with splines that connects it to its respective door linkage and two integral mounting tabs that allow the actuator to be secured to the front HVAC housing. The front blend door actuators do not require mechanical indexing to the blend-air doors, as they are electronically calibrated by the A/C-heater control. The A/C-heater control must be recalibrated each time an actuator motor is replaced. The blend door actuators are connected to the A/Cheater control through the vehicle electrical system by a dedicated two-wire lead and connector of the HVAC wire harness. The blend door actuator(s) can move the blend-air door(s) in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the blend-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the blend-air door moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the blend-air door stops and will not move. The A/C-heater control uses a feedback signal positioning system to monitor the operation and relative position of the blend door actuator(s) and the blend-air door(s). The A/C-heater control learns the blend-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the blend door actuator circuits. The blend door actuators are diagnosed using a DRBIII(R) scan tool. The blend door actuators cannot be adjusted or repaired and, if faulty or damaged, they must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator > Page 7203 Rear Blend Door Actuator The rear blend door actuator is a reversible, 12-volt Direct Current (DC), servo motor. The single blend door actuator for the rear heating-A/C system is located on the outboard side of the rear HVAC housing and is mechanically connected to the blend-air door. The rear blend door actuator is interchangeable with the actuator for the rear mode-air door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Each actuator also has an identical output shaft with splines that connects it to its respective door linkage and two integral mounting tabs that allow the actuator to be secured to the rear HVAC housing. The blend door actuator does not require mechanical indexing to the blend-air door, as it is electronically calibrated by the A/C-heater control. The A/C-heater control must be recalibrated each time an actuator motor is replaced. The rear blend door actuator is connected to the front A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the rear HVAC wire harness. The rear blend door actuator can move the rear blend-air door in two directions. When the front A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the rear blend-air door will move in one direction. When the front A/C-heater control reverses the polarity of the voltage to the motor, the rear blend-air door moves in the opposite direction. When the front A/C-heater control makes the voltage to both connections high or both connections low, the rear blend-air door stops and will not move. The front A/C-heater control uses a feedback signal positioning system to monitor the operation and relative position of the rear blend door actuator and the blend-air door. The front A/C-heater control learns the rear blend-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the rear blend door actuator circuits. The rear blend door actuator is diagnosed using a DRBIII(R) scan tool. The rear blend door actuator cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator > Page 7204 Air Door Actuator / Motor: Description and Operation Mode Door Actuator Front Mode Door Actuator The mode door actuator for the front heating-A/C system is a reversible, 12-volt Direct Current (DC), servo motor. The single mode door actuator is located on the driver side end of the front HVAC air distribution housing, close to the top of the distribution housing. The mode door actuator is mechanically connected to the mode door. The front mode door actuator is interchangeable with the actuators for the blend-air doors and the recirculation-air door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Each actuator also has an identical output shaft with splines that connects it to its respective door linkage and two integral mounting tabs that allow the actuator to be secured to the front HVAC housing. The front mode door actuator does not require mechanical indexing to the mode-air doors, as it is electronically calibrated by the A/C-heater control. The A/C-heater control must be recalibrated each time an actuator motor is replaced. The mode door actuator is connected to the A/Cheater control through the vehicle electrical system by a dedicated two-wire lead and connector of the HVAC wire harness. The mode door actuator can move the mode-air doors in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the mode-air doors will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the mode-air doors move in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the mode-air doors stop and will not move. The A/C-heater control uses a feedback signal positioning system to monitor the operation and relative position of the mode door actuator and the mode- air doors. The A/C-heater control learns the mode-air doors stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the mode door actuator circuits. The mode door actuator is diagnosed using a DRBIII(R) scan tool. The mode door actuator cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator > Page 7205 Rear Blend Door Actuator The mode door actuator for the rear heating-A/C system is a reversible, 12-volt Direct Current (DC), servo motor. The mode door actuator is located on the outboard side of the rear HVAC housing, above the blend door actuator. The mode door actuator is mechanically connected to the mode door. The rear mode door actuator is interchangeable with the actuator for the rear blend-air door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Each actuator also has an identical output shaft with splines that connects it to its respective door linkage and two integral mounting tabs that allow the actuator to be secured to the rear HVAC housing. The rear mode door actuator does not require mechanical indexing to the mode-air door, as it is electronically calibrated by the front A/C-heater control. The A/C-heater control must be recalibrated each time an actuator motor is replaced. The rear mode door actuator is connected to the front heater-A/C control module through the vehicle electrical system by a dedicated two-wire take out and connector of the rear HVAC wire harness. The rear mode door actuator can move the mode door in two directions. When the front heater-A/C control module pulls the voltage on one side of the motor connection high and the other connection low, the rear mode door will move in one direction. When the module reverses the polarity of the voltage to the motor, the rear mode door moves in the opposite direction. When the module makes the voltage to both connections high or both connections low, the mode door stops and will not move. These same motor connections also provide a feedback signal to the front heater-A/C control module. This feedback signal allows the module to monitor the operation and relative positions of the rear mode door actuator and the mode door. The front heater-A/C control module learns the rear mode door stop positions during the calibration procedure and will store a Diagnostic Trouble Code (DTC) for any problems it detects in the mode door actuator circuits.The rear mode door actuator can be diagnosed using a DRBIII(R) scan tool. The rear mode door actuator cannot be adjusted or repaired and, if damaged or faulty, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator > Page 7206 Air Door Actuator / Motor: Description and Operation Recirculation Door Actuator Recirculation Door Actuator The recirculation door actuator is a reversible, 12 volt direct current (DC), servo motor. The recirculation door actuator is located on the bottom of the HVAC air inlet housing and is directly connected to the pivot shaft of the recirculation-air door. The recirculation door actuator is interchangeable with the actuators for the blend-air door(s) and the mode-air doors. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Each actuator also has an identical output shaft with splines that connects it to its door linkage and two integral mounting tabs that allow the actuator to be secured to the air inlet housing. The recirculation door actuator does not require mechanical indexing to the recirculation-air door, as it is electronically calibrated by the A/C heater control. The A/C-heater control must be recalibrated each time an actuator motor is replaced. The recirculation door actuator is connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the HVAC wire harness. The recirculation door actuator can move the recirculation-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the recirculation-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the recirculation-air door moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the recirculation-air door stops and will not move. The A/C-heater control uses a feedback signal positioning system to monitor the operation and relative position of the recirculation door actuator and the recirculation-air door. The A/C-heater control learns the recirculation-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the recirculation door actuator circuits. The recirculation door actuator is diagnosed using a DRBIII(R) scan tool. The recirculation door actuator cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator Air Door Actuator / Motor: Service and Repair Blend Door Actuator Front REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The single zone heater-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door. 1. Disconnect and isolate the negative battery cable. 2. Remove the silencer from beneath the driver side end of the instrument panel. Blend Door Actuator 3. Disconnect the wire harness connector from the blend door actuator being serviced. 4. Remove the two screws that secure the blend door actuator being serviced to the HVAC air distribution housing and remove the actuator. INSTALLATION 1. Position the blend door actuator being serviced onto the air distribution housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the blend air door linkage. 2. Install the two screws that secure the blend door actuator being serviced to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.). 3. Connect the HVAC wire harness connector to the blend door actuator being serviced. 4. Install the silencer under the driver side end of the instrument panel. 5. Reconnect the negative battery cable and calibrate the A/C-heater control. Rear REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel. 3. Remove the two screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel. 4. Remove the screw that secures the back of the rear HVAC housing to the right D-pillar. 5. Remove the screw that secures the front of the rear HVAC housing to the right quarter inner panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator > Page 7209 Rear HVAC Mode Door Actuator 6. Carefully pull the top of the rear HVAC housing away from the right quarter inner panel far enough to reach between the rear HVAC housing and the quarter inner panel to access the rear blend door actuator. 7. Remove the two screws that secure the rear blend door actuator to the rear HVAC housing. 8. Pull the rear blend door actuator away from the rear HVAC housing far enough to disengage the actuator output shaft from the rear blend door pivot. 9. Raise the rear blend door actuator far enough to access and disconnect the rear HVAC wire harness connector from the actuator. 10. Remove the rear blend door actuator from between the rear HVAC housing and the quarter inner panel. INSTALLATION 1. Position the rear blend door actuator between the rear HVAC housing and the quarter inner panel. 2. Connect the rear HVAC wire harness connector to the rear blend door actuator. 3. Position the rear blend door actuator onto the rear HVAC housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the blend air door pivot. 4. Install the two screws that secure the rear blend door actuator to the rear HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.). 5. Push the top of the rear HVAC housing back into position against the right quarter inner panel. 6. Install the screw that secures the front of the rear HVAC housing to the right quarter inner panel. Tighten the screw to 11 N.m (97 in. lbs.). 7. Install the screw that secures the back of the rear HVAC housing to the right D-pillar. Tighten the screw to 11 N.m (97 in. lbs.). 8. Install the two screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel. Tighten the screws to 2 N.m (17 in. lbs.). 9. Reinstall the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel. 10. Reconnect the negative battery cable and calibrate the A/C-heater control. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator > Page 7210 Air Door Actuator / Motor: Service and Repair Mode Door Actuator Front REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. 1. Disconnect and isolate the negative battery cable. 2. Remove the silencer from beneath the driver side end of the instrument panel. Mode Door Actuator 3. Disconnect the wire harness connector from the mode door actuator. 4. Remove the two screws that secure the mode door actuator to the HVAC air distribution housing and remove the actuator. INSTALLATION 1. Position the mode door actuator onto the HVAC air distribution housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode door linkage. 2. Install the two screws that secure the mode door actuator to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.). 3. Connect the wire harness connector to the mode door actuator. 4. Install the silencer under the driver side end of the instrument panel. 5. Reconnect the negative battery cable and calibrate the A/C-heater control. Rear REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel. 3. Remove the two screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel. 4. Remove the screw that secures the back of the rear HVAC housing to the right D-pillar. 5. Remove the screw that secures the front of the rear HVAC housing to the right quarter inner panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator > Page 7211 Rear HVAC Blend Door Actuator 6. Carefully pull the top of the rear HVAC housing away from the right quarter inner panel far enough to reach between the rear HVAC housing and the quarter inner panel to access the rear mode door actuator. 7. Remove the two screws that secure the mode door actuator to the rear HVAC housing. 8. Pull the mode door actuator away from the rear HVAC housing far enough to disengage the actuator output shaft from the mode door linkage. 9. Raise the mode door actuator far enough to access and disconnect the rear HVAC wire harness connector from the actuator 10. Remove the rear mode door actuator from between the rear HVAC housing and the quarter inner panel. INSTALLATION 1. Position the mode door actuator between the rear HVAC housing and the quarter inner panel. 2. Reconnect the rear HVAC wire harness connector to the rear mode door actuator. 3. Position the rear mode door actuator onto the rear HVAC housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode door linkage. 4. Install the two screws that secure the rear mode door actuator to the rear HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.). 5. Push the top of the rear HVAC housing back into position against the right quarter inner panel. 6. Install the screw that secures the front of the rear HVAC housing to the right quarter inner panel. Tighten the screw to 11 N.m (97 in. lbs.). 7. Install the screw that secures the back of the rear HVAC housing to the right D-pillar. Tighten the screw to 11 N.m (97 in. lbs.). 8. Install the two screws that secure the top of the quarter trim panel attaching bracket to the quarter inner panel. Tighten the screws to 2 N.m (17 in. lbs.). 9. Reinstall the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel. 10. Reconnect the battery negative cable. 11. Perform the heater-A/C control calibration procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator > Page 7212 Air Door Actuator / Motor: Service and Repair Recirculation Door Actuator REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. 1. Disconnect and isolate the negative battery cable. 2. Pull the carpet on the passenger side front floor away from the dash panel far enough to access the recirculation door actuator. Recirculation Door Actuator 3. Disconnect the HVAC wire harness connector from the recirculation door actuator. 4. Remove the two screws that secure the recirculation door actuator to the air inlet housing and remove the actuator. INSTALLATION 1. Position the recirculation door actuator onto the air inlet housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the recirculation-air door pivot shaft. 2. Install the two screws that secure the recirculation door actuator to the air inlet housing. Tighten the screws to 2 N.m (17 in. lbs.). 3. Connect the HVAC wire harness connector to the recirculation door actuator. 4. Reposition the carpet on the passenger side front floor back up to the dash panel. 5. Reconnect the negative battery cable and calibrate the A/C-heater control. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center Bezel Outlets Air Duct: Service and Repair Center Bezel Outlets REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Take the proper precautions to protect the front face of the instrument panel center bezel from cosmetic damage during this service procedure. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a workbench. Center Air Outlets 3. If the vehicle is equipped with the automatic temperature control (ATC) heating-A/C system, disconnect the infrared temperature sensor jumper harness from the infrared temperature sensor located at the bottom of the middle outlet. 4. Remove the three screws that secure the bottom of the center bezel outlet housing to the center bezel and disengage the retaining tabs at the top of the housing. 5. Remove the center bezel outlets and housing from the center bezel as an assembly. INSTALLATION 1. Position the center bezel outlets and housing assembly onto the back of the instrument panel center bezel and engage the retaining tabs to the top of the bezel. 2. Install the bottom of the outlet housing to the center bezel and install the three retaining screws. Tighten the screws to 2 N.m (17 in. lbs.). 3. If the vehicle is equipped with the ATC heating-A/C system, connect the infrared temperature sensor jumper harness to the infrared temperature sensor located at the bottom of the center outlet. 4. Install the center bezel onto the instrument panel. 5. Reconnect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center Bezel Outlets > Page 7217 Air Duct: Service and Repair Instrument Panel Outlets REMOVAL Instrument Panel Outlet - Left Side Shown 1. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the outer perimeter of the instrument panel outlet to the instrument panel top pad and remove the outlet. INSTALLATION 1. Position the instrument panel outlet to the instrument panel top pad. 2. Using hand pressure, install the instrument panel outlet firmly and evenly into the instrument panel top pad until the retaining tabs fully engage. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center Bezel Outlets > Page 7218 Air Duct: Service and Repair Air Outlets REMOVAL Overhead Outlet 1. Using a trim stick C-4755 or equivalent, disengage the thumb wheel end of the overhead air outlet from the pivot pin in the headliner bezel. 2. Disengage the opposite end of the overhead air outlet from the pivot pin in the headliner bezel and remove the air outlet. INSTALLATION 1. Position the overhead air outlet into the opening in the headliner bezel. 2. Engage the non-thumb wheel end of the overhead air outlet onto the pivot pin in the headliner bezel. 3. Using hand pressure, push the thumb wheel end of the overhead air outlet onto the pivot pin until fully engaged. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center Bezel Outlets > Page 7219 Air Duct: Service and Repair Distribution Duct REMOVAL 1. Remove the trim panels from the inner right quarter panel and the right D-pillar. Rear Distribution Duct 2. Slide the rear distribution duct upwards and disengage it from the outlet located at the top of the rear HVAC housing. 3. While pulling the lower end of the rear distribution duct away from the rear HVAC housing, disengage the upper end of the distribution duct from the headliner duct and remove the duct. INSTALLATION 1. Position the upper end of the rear distribution duct to the headliner duct. 2. Install the upper end of the rear distribution duct onto the headliner duct and align the lower end of the duct with the outlet at the top of the rear HVAC housing. 3. Slide the rear distribution duct downward and engage it onto the outlet located at the top of the rear HVAC housing. 4. Install the trim panels onto the inner right quarter panel and the right D-pillar. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center Bezel Outlets > Page 7220 Air Duct: Service and Repair Center Bezel Outlets REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Take the proper precautions to protect the front face of the instrument panel center bezel from cosmetic damage during this service procedure. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a workbench. Center Air Outlets 3. If the vehicle is equipped with the automatic temperature control (ATC) heating-A/C system, disconnect the infrared temperature sensor jumper harness from the infrared temperature sensor located at the bottom of the middle outlet. 4. Remove the three screws that secure the bottom of the center bezel outlet housing to the center bezel and disengage the retaining tabs at the top of the housing. 5. Remove the center bezel outlets and housing from the center bezel as an assembly. INSTALLATION 1. Position the center bezel outlets and housing assembly onto the back of the instrument panel center bezel and engage the retaining tabs to the top of the bezel. 2. Install the bottom of the outlet housing to the center bezel and install the three retaining screws. Tighten the screws to 2 N.m (17 in. lbs.). 3. If the vehicle is equipped with the ATC heating-A/C system, connect the infrared temperature sensor jumper harness to the infrared temperature sensor located at the bottom of the center outlet. 4. Install the center bezel onto the instrument panel. 5. Reconnect the battery negative cable. Instrument Panel Outlets REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center Bezel Outlets > Page 7221 Instrument Panel Outlet - Left Side Shown 1. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the outer perimeter of the instrument panel outlet to the instrument panel top pad and remove the outlet. INSTALLATION 1. Position the instrument panel outlet to the instrument panel top pad. 2. Using hand pressure, install the instrument panel outlet firmly and evenly into the instrument panel top pad until the retaining tabs fully engage. Air Outlets REMOVAL Overhead Outlet 1. Using a trim stick C-4755 or equivalent, disengage the thumb wheel end of the overhead air outlet from the pivot pin in the headliner bezel. 2. Disengage the opposite end of the overhead air outlet from the pivot pin in the headliner bezel and remove the air outlet. INSTALLATION 1. Position the overhead air outlet into the opening in the headliner bezel. 2. Engage the non-thumb wheel end of the overhead air outlet onto the pivot pin in the headliner bezel. 3. Using hand pressure, push the thumb wheel end of the overhead air outlet onto the pivot pin until fully engaged. Distribution Duct REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center Bezel Outlets > Page 7222 1. Remove the trim panels from the inner right quarter panel and the right D-pillar. Rear Distribution Duct 2. Slide the rear distribution duct upwards and disengage it from the outlet located at the top of the rear HVAC housing. 3. While pulling the lower end of the rear distribution duct away from the rear HVAC housing, disengage the upper end of the distribution duct from the headliner duct and remove the duct. INSTALLATION 1. Position the upper end of the rear distribution duct to the headliner duct. 2. Install the upper end of the rear distribution duct onto the headliner duct and align the lower end of the duct with the outlet at the top of the rear HVAC housing. 3. Slide the rear distribution duct downward and engage it onto the outlet located at the top of the rear HVAC housing. 4. Install the trim panels onto the inner right quarter panel and the right D-pillar. Floor Distribution Ducts REMOVAL 1. Roll back the carpet on the front floor from under the instrument panel toward the rear of the vehicle. Floor Distribution Ducts - LHD Shown, RHD Typical 2. Lift the center floor distribution duct upward far enough to disengage its locator hole from the weld stud on the front floor panel. 3. Pull the center floor distribution duct rearward and disengage it from the floor outlet of the front HVAC housing. 4. Disassemble the right and/or left floor distribution ducts from the center floor distribution duct as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center Bezel Outlets > Page 7223 INSTALLATION 1. Install the right and/or left floor distribution duct onto the center floor distribution duct as required. 2. Position the center floor distribution duct under the instrument panel center stack and engage it to the floor outlet of the front HVAC housing. 3. Align the locator hole on the center floor distribution duct with the weld stud on the front floor panel and install the distribution duct onto the weld stud. 4. Install the carpet onto the front floor panel and under the instrument panel. Rear Floor Heat Duct REMOVAL 1. Remove the trim panel from the right inner quarter panel. Rear Floor Heat Duct 2. Remove the two screws that secure the rear floor heat duct to the right inner quarter panel. 3. Slide the rear floor heat duct forward to disengage it from the rear HVAC housing and remove the duct. INSTALLATION 1. Position the rear floor heat duct to rear HVAC housing. 2. Slide the rear floor heat duct rearward to engage it to the rear HVAC housing. 3. Install the two screws that secure the rear floor heat duct to the right inner quarter panel. Tighten the screws to 2 N.m (17 in. lbs.). 4. Install the trim panel onto the right inner quarter panel. Demister Outlets REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Center Bezel Outlets > Page 7224 Demister Outlet 1. Using a trim stick C-4755 or equivalent, disengage the retaining tabs that secure the outer perimeter of the demister outlet to the instrument panel top pad and remove the outlet. INSTALLATION 1. Position the demister outlet to the instrument panel top pad. 2. Using hand pressure, install the demister outlet firmly and evenly into the instrument panel top pad until the retaining tabs fully engage. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair Air Register: Service and Repair REAR HVAC LOUVER REMOVAL 1. Using a trim stick (C-4755), pry edge of louver from bezel. 2. Remove HVAC louver from bezel. Fig. 44 3. Using a trim stick, pry lower edge of HVAC bezel away from headlining (Fig. 44). 4. Remove louver from vehicle. INSTALLATION 1. Place bezel in position in HVAC duct opening. 2. Push inward on bezel until clips snap in place. Verify that all four clips have been engaged to the bezel and that the bezel is flush to the headlining 3. Position HVAC louver to bezel. 4. Snap both ends of the louver into HVAC bezel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7231 Ambient Temperature Sensor / Switch HVAC: Diagrams Ambient Temperature Sensor ATC Remote Sensor (ATC) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Infrared Temperature Sensor Ambient Temperature Sensor / Switch HVAC: Description and Operation Infrared Temperature Sensor Infrared Temperature Sensor - RS Shown, RG Typical The infrared temperature sensor consists of two infrared transducers that are concealed behind a clear lens located near the top of the instrument panel center bezel. These sensors are used only on models equipped with the optional automatic temperature control (ATC) heating-A/C system. A molded plastic connector receptacle on the bottom of the panel outlet unit is concealed behind the center bezel. A short, dedicated jumper wire harness routed behind the center bezel connects the sensors directly to the ATC A/C-heater control module near the bottom of the center bezel. The infrared temperature sensor is integral to the center bezel panel outlet. The infrared sensor detects thermal radiation emitted by the driver and front passenger seat occupants and their surroundings and converts its data into a linear pulse width modulated (PWM) output signal which is read by the automatic temperature control (ATC) A/C-heater control. The ATC A/C-heater control uses the infrared sensor data as one of the inputs necessary to automatically control the interior cabin temperature level. By using thermal radiation (surface temperature) measurement, rather than an air temperature measurement, the ATC heating-A/C system is able to adjust itself to the comfort level as perceived by the occupant. This allows the ATC system to compensate for other ambient conditions affecting comfort levels, such as solar heat gain or evaporative heat loss. The ATC system logic responds to the infrared sensor message by calculating and adjusting the air flow temperature and air flow rate needed to properly obtain and maintain the selected comfort level temperature of the occupants. The A/C-heater control continually monitors the infrared sensor circuits, and will store diagnostic trouble codes (DTCs) for any problem it detects. The infrared sensor is diagnosed using a DRBIII(R) scan tool. The infrared sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Infrared Temperature Sensor > Page 7234 Ambient Temperature Sensor / Switch HVAC: Description and Operation Ambient Temp Sensor Ambient air temperature is monitored by the overhead console through ambient temperature messages received from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus circuit. The PCM receives a hard wired input from the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the headlamp mounting module grille opening, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent by the Powertrain Control Module (PCM). The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the PCM. Based upon the resistance in the sensor, the PCM senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. The PCM then sends the proper ambient temperature messages to the Electronic Vehicle Information Center (EVIC)/Compass Mini-Trip Computer (CMTC) over the Programmable Communication Interface (PCI) data bus. The thermometer function is supported by the ambient temperature sensor, a wiring circuit, the PCM, the PCI data bus, and the Electronics module. If any portion of the ambient temperature sensor circuit fails, the PCM will self-diagnose the circuit. The ambient temperature sensor circuit can also be diagnosed manually. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect to determine the cause. For complete circuit diagrams, refer to the appropriate wiring information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Testing and Inspection > Ambient Temperature Sensor Ambient Temperature Sensor / Switch HVAC: Testing and Inspection Ambient Temperature Sensor 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector. 2. Measure the resistance of the ambient temperature sensor. At room temperature (approx. 68° F), the sensor resistance should be between 10-13 Kilohms. The sensor resistance should be between these two values at 68° F. If the resistance is out of range replace the ambient temperature sensor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Testing and Inspection > Ambient Temperature Sensor > Page 7237 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection Ambient Temperature Sensor Circuit 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the Powertrain Control Module (PCM) wire harness connector. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor wire harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the PCM wire harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Remove the jumper wire from the body half of the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the PCM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted sensor return circuit as required. 5. Check for continuity between the ambient temperature sensor signal circuit cavity of the PCM wire harness connector and a good ground. There should be no continuity. If OK, Driver/Vehicle Information Display to determine the cause. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Testing and Inspection > Page 7238 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. From behind the front bumper fascia, remove the screw holding the sensor to the radiator closure panel. 3. Disconnect the sensor electrical connector. 4. Remove the sensor from vehicle. INSTALLATION 1. Position the sensor in the vehicle and connect the sensor electrical connector. 2. From behind the front bumper fascia, install the sensor mounting screw. 3. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Connector Views Blower Motor: Connector Views Rear Blower Motor Power Module C1 (3 Zone ATC) Rear Blower Motor Power Module C2 (3 Zone ATC) Front Blower Module C1 (ATC) Front Blower Module C2 (ATC) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Operation - Front Blower Motor: Description and Operation Operation - Front Blower Motor The blower motor is a 12-volt, direct current (DC) motor mounted within a plastic housing with a squirrel cage-type blower wheel that is secured to the blower motor shaft and an integral wire harness with a grommet and connector. The blower motor and wheel is located in the air inlet housing at the passenger side end of the HVAC housing. The blower motor can be accessed for service from underneath the instrument panel. The front blower motor is used to control the velocity of air moving through the front HVAC housing by spinning the blower wheel within the housing at the selected or programed speed (depending on application). On models equipped with the manual temperature control (MTC) heating-A/C system, the front blower motor will operate whenever the ignition switch is in the On position and the blower control switch is in any position except Off. On models equipped with the automatic temperature control (ATC) heating-A/C system, the front blower motor will operate whenever the ignition switch is in the On position and the A/Cheater control power is turned on. The front blower motor relay output circuit is protected by a fuse in the integrated power module (IPM) located in the engine compartment. In the MTC system, the front blower motor speed is controlled by regulating the path to ground through the blower control switch and the blower motor resistor. In the ATC system, the front blower motor speed is controlled by an electronic blower motor power module, which uses a pulse width modulated input from the A/C-heater control and a feedback signal from the blower motor to regulate the blower motor ground path. On both systems, the front blower motor receives battery current whenever the front blower motor relay is energized. The front blower motor and blower motor wheel are factory balanced and cannot be adjusted or repaired. If faulty or damaged, the front blower motor and blower wheel must be replaced as an assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Operation - Front > Page 7245 Blower Motor: Description and Operation Rear Rear Blower Motor The blower motor for the rear heating-A/C system is a 12-volt, direct current (DC) motor with an integral wire harness and connector that is mounted within a plastic housing with a squirrel cage-type blower wheel, which is secured to the blower motor shaft. The blower motor and wheel is located on the outboard side of the rear HVAC housing. The blower motor can be accessed for service by removing the rear HVAC housing. The rear blower motor is used to control the velocity of air moving through the rear HVAC housing by spinning the blower wheel within the housing at the selected or programed speed (depending on application). On models equipped with the manual temperature control (MTC) heating-A/C system, the rear blower motor will operate only whenever the ignition switch is in the On position, the front blower control switch is in any position except Off and the rear blower control switch on the front A/C-heater control is in any position except Off. On models equipped with the automatic temperature control (ATC) heating-A/C system, the blower motor will operate whenever the ignition switch is in the On position, the A/C-heater control power is turned on and the rear blower control switch on the front A/C-heater control is in any position except Off. The rear blower motor can only be turned off by turning off the rear system at the front A/C-heater control. The rear blower motor relay output circuit is protected by a fuse in the integrated power module (IPM) located in the engine compartment. In the MTC system, the rear blower motor speed is controlled by regulating the path to ground through the blower control switch and the blower motor resistor. In the ATC system, the rear blower motor speed is controlled by an electronic blower motor power module, which uses a pulse width modulated input from the A/C-heater control and a feedback signal from the rear blower motor to regulate the blower motor ground path. The rear blower motor receives battery current whenever the rear blower motor relay is energized. For diagnosis and testing of the rear blower motor, refer to testing. The rear blower motor and blower motor wheel are factory balanced and cannot be adjusted or repaired. If faulty or damaged, the rear blower motor and blower wheel must be replaced as an assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Page 7246 Blower Motor: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. For circuit descriptions and diagrams, refer to Air Conditioning/Heater Wiring Diagrams. Possible causes of an inoperative front or rear blower motor include: - Faulty fuse (the fuse is located in the integrated power module (IPM) in the engine compartment) - Faulty blower motor circuit wiring or wire harness connectors - Faulty blower motor resistor or power module (depending on application) - Faulty blower motor relay - Faulty blower motor switch - Faulty blower motor. VIBRATION Possible causes of front or rear blower motor vibration include: - Improper blower motor mounting - Improper blower wheel mounting - Blower wheel out of balance or deformed - Foreign material in blower wheel causing out of balance condition - Blower motor faulty. NOISE To determine if the front or rear blower motor is the source of the noise, simply switch the front or rear blower motor from Off to On. To verify that the blower motor is the source of the noise, unplug the blower motor wire harness connector and operate the heating-A/C system. If the noise goes away, possible causes include: - Foreign material in the HVAC housing - Improper blower motor mounting - Improper blower wheel mounting - Blower motor faulty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front Blower Motor Blower Motor: Service and Repair Front Blower Motor REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN AN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH OR DEATH. NOTE: The blower motor is located on the passenger side of the vehicle under the instrument panel. The blower motor can be removed from the vehicle without having to remove the HVAC housing. 1. Disconnect and isolate the negative battery cable. 2. Remove the passenger side cowl trim panel. 3. Position the carpet to access the front upper screw that secures the air inlet housing. 4. Remove the recirculation door actuator. 5. Disconnect the blower motor wire lead connector from the blower motor resistor or power module, depending on application. Lower Air Inlet Housing 6. Remove the one screw (from the top) that secures the lower air inlet housing to the upper air inlet housing. 7. Remove the four screws (from the bottom) that secure the lower air inlet housing to the upper air inlet housing and remove the lower HVAC housing. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front Blower Motor > Page 7249 Blower Motor Wire Lead Grommet 8. Push the rubber grommet through the opening in the lower air inlet housing. 9. Route the blower motor wire lead through the opening in the lower air inlet housing and remove the lower air inlet housing from the vehicle. 10. Position the recirculation-air door as necessary to access and remove the three screws that secure the blower motor to the lower half of the HVAC housing. 11. Gently flex the recirculation air door downward to gain access to remove the blower motor from the HVAC housing. NOTE: To aid in installation, note the position of the blower motor mounting tabs prior to removal. Blower Motor Mounting Tabs 12. Remove the blower motor from the HVAC housing by rotating and tilting the blower motor as necessary. INSTALLATION 1. Gently flex the recirculation-air door downward to gain access to install the blower motor into the HVAC housing. 2. Position the blower motor to the HVAC housing and tilt and rotate the blower motor as necessary to install it into the HVAC housing. 3. Align the blower motor mounting tabs to the locations noted during removal and install the three screws that secure the blower motor to the HVAC housing. Tighten the screws to 2 N·m (17 in. lbs.). 4. Route the blower motor wire lead through the opening in the lower air inlet housing and seat the rubber grommet. 5. Position the recirculation door pivot shaft into the lower air inlet housing and install the inlet housing. 6. Install the four screws (from the bottom) that secure the lower air inlet housing to the upper air inlet housing and the lower HVAC housing. Tighten the screws to 2 N·m (17 in. lbs.). 7. Install the one screw (from the top) that secures the lower air inlet housing to the upper air inlet housing. Tighten the screw to 2 N·m (17 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front Blower Motor > Page 7250 8. Connect the blower motor wire lead connector to the blower motor resistor or power module, depending on application. 9. Install the recirculation door actuator. 10. Reposition the carpet. 11. Install the passenger side cowl trim panel. 12. Reconnect the negative battery cable. 13. Perform the heater-A/C control calibration procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Front Blower Motor > Page 7251 Blower Motor: Service and Repair Rear Blower Motor NOTE: On the manual temperature control (MTC) heating-A/C system, the rear blower motor wire harness is connected to the rear HVAC wire harness. On the automatic temperature control (ATC) heating-A/C system, the rear blower motor wire harness is connected to the rear blower motor power module. REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Remove the rear HVAC housing and place it on a workbench. Rear Blower Motor 2. Disconnect the wire harness connector for the rear blower motor. 3. Remove the three screws that secure the rear blower motor to the outboard side of the rear HVAC housing and remove the blower motor. INSTALLATION 1. Position the rear blower motor onto the rear HVAC housing. 2. Install the three screws that secure the rear blower motor to the rear HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.). 3. Connect the wire harness connector for the rear blower motor. 4. Install the rear HVAC housing. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 7255 Blower Motor Relay: Diagrams 8w-10-3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 7256 8w-10-5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Page 7257 Front Blower Motor Relay Rear Blower Motor Relay Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay: Description and Operation Front Front Blower Motor Relay The blower motor relay for the front heating-A/C system is an International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns. The front blower motor relay is located in the integrated power module (IPM) in the engine compartment. The front blower motor relay is an electromechanical switch that uses a low current input from the front control module (FCM) to control the high current output to the blower motor resistor (manual temperature control) or the blower motor power module (automatic temperature control). The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the blower motor. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The blower motor relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the blower motor relay include: - The common feed terminal (30) receives a battery current input from the battery through a B(+) circuit at all times. - The coil ground terminal (85) receives a ground input through the front/rear blower motor relay control circuit only when the FCM electronically pulls the control circuit to ground. - The coil battery terminal (86) receives a battery current input from the battery through a B(+) circuit at all times. - The normally open terminal (87) provides a battery current output to the blower motor resistor (manual temperature control) or blower motor power module (automatic temperature control) through a fuse in the IPM on the fused front blower motor relay output circuit only when the blower motor relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the blower motor relay coil is de-energized. The blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard relay and for complete HVAC wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description and Operation > Front > Page 7260 Blower Motor Relay: Description and Operation Rear Rear Blower Motor Relay The blower motor relay for the rear heating-A/C system is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns. The rear blower motor relay is located in the integrated power module (IPM) in the engine compartment. The rear blower motor relay is an electromechanical switch that uses a low current input from the front control module (FCM) to control the high current output to the rear blower motor resistor (manual temperature control) or rear blower motor power module (automatic temperature control). The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the rear blower motor. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear blower motor relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the rear blower motor relay include: - The common feed terminal (30) receives a battery current input from the battery through a B(+) circuit at all times. - The coil ground terminal (85) receives a ground input through the front/rear blower motor relay control circuit only when the FCM electronically pulls the control circuit to ground. - The coil battery terminal (86) receives a battery current input from the battery through a B(+) circuit at all times. - The normally open terminal (87) provides a battery current output to the blower motor resistor (manual temperature control) or blower motor power module (automatic temperature control) through a fuse in the IPM on the fused rear blower motor relay output circuit only when the rear blower motor relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the rear blower motor relay coil is de-energized. Refer to the appropriate wiring information for diagnosis and testing of the micro-relay and for complete HVAC wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Service and Repair > Front Blower Motor Relay: Service and Repair Front REMOVAL 1. Disconnect and isolate the negative battery cable. Front Blower Motor Relay 2. Remove the cover from the integrated power module (IPM) located in the engine compartment. NOTE: Refer to the fuse and relay map on the IPM cover for front blower motor relay location. 3. Remove the front blower motor relay from the IPM. INSTALLATION NOTE: Refer to the fuse and relay map on the cover of the integrated power module (IPM) for front blower motor relay location. 1. Position the front blower motor relay to the proper receptacle in the IPM. 2. Align the front blower motor relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Service and Repair > Front > Page 7263 Blower Motor Relay: Service and Repair Rear REMOVAL 1. Disconnect and isolate the negative battery cable. Rear Blower Motor Relay 2. Remove the cover from the integrated power module (IPM). NOTE: Refer to the fuse and relay map on the IPM cover for rear blower motor relay location. 3. Remove the rear blower motor relay from the IPM. INSTALLATION NOTE: Refer to the fuse and relay map on the cover of the integrated power module (IPM) for rear blower motor relay location. 1. Position the rear blower motor relay to the proper receptacle in the IPM. 2. Align the rear blower motor relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams Blower Motor Resistor: Diagrams Blower Motor Resistor C1 (MTC) Blower Motor Resistor C2 (MTC) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Front Blower Motor Resistor: Description and Operation Front Blower Motor Resistor - Typical A blower motor resistor is used on vehicles equipped with the front manual temperature control (MTC) heating-A/C system. Vehicles equipped with the automatic temperature control (ATC) heating-A/C system use a blower motor power module, instead of the blower motor resistor. The front blower motor resistor is mounted to the rear of the front HVAC housing, directly behind the glove box. The front blower motor resistor consists of a molded plastic mounting plate with an integral wire connector receptacle. Concealed behind the mounting plate are coiled resistor wires contained within a ceramic heat sink. The front blower motor resistor is accessed for service by removing the glove box. The front blower motor resistor is connected to the vehicle electrical system through a dedicated wire lead and connector of the front HVAC wire harness. The front blower motor resistor has multiple resistor wires, each of which will reduce the current flow through the front blower motor to change the blower motor speed. The blower motor control in the manual temperature control system directs the ground path for the front blower motor through the correct resistor wire to obtain the selected speed. With the blower motor control in the lowest speed position, the ground path for the front blower motor is applied through all of the resistor wires. Each higher speed selected with the blower motor control applies the blower motor ground path through fewer of the resistor wires, increasing the blower motor speed. The front blower motor resistor cannot be adjusted or repaired and, if faulty or damaged (such as a cracked ceramic heat sink), it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Front > Page 7269 Blower Motor Resistor: Description and Operation Rear Rear Blower Motor Resistor A rear blower motor resistor is used on vehicles equipped with the manual temperature control (MTC) heating-A/C system. Vehicles equipped with the automatic temperature control (ATC) heating-A/C system use a rear blower motor power module, instead of the rear blower motor resistor. The rear blower motor resistor is mounted to the rear HVAC housing, directly above the A/C expansion valve. The rear blower motor resistor consists of a molded plastic mounting plate with an integral connector receptacle. Concealed behind the mounting plate is an electrical circuit board with two resistors and a thermal fuse. The rear blower motor resistor is accessed for service by removing the right quarter and D-pillar trim panels. The rear blower motor resistor is connected to the vehicle electrical system through a dedicated take out and connector of the rear HVAC wire harness. The rear blower motor resistor has an electrical circuit board with two resistors, each of which will reduce the current flow through the rear blower motor to change the blower motor speed. The blower motor switch in the manual temperature control system directs the ground path for the rear blower motor through the correct resistor to obtain the selected speed. With the blower motor switch in the lowest speed position, the ground path for the motor is applied through both resistors. Each higher speed selected with the blower motor switch applies the blower motor ground path through fewer of the resistors, increasing the blower motor speed. When the blower motor switch is in the highest speed position, the blower motor resistors are bypassed and the blower motor receives a direct path to ground through the blower motor switch. The rear blower motor resistor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Front Blower Motor Resistor Blower Motor Resistor: Testing and Inspection Front Blower Motor Resistor WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: For circuit descriptions and diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector from the blower motor resistor. 3. Using an ohmmeter, check for continuity between all of the blower motor resistor terminals. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor switch and the blower motor resistor or blower motor as required. If not OK, replace the faulty blower motor resistor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Front Blower Motor Resistor > Page 7272 Blower Motor Resistor: Testing and Inspection Rear Blower Motor Resistor WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: For circuit descriptions and diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector from the blower motor resistor. 3. Using an ohmmeter, check for continuity between all of the blower motor resistor terminals. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor switch and the blower motor resistor or blower motor as required. If not OK, replace the faulty blower motor resistor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Front Blower Motor Resistor: Service and Repair Front REMOVAL WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. - THE BLOWER MOTOR RESISTOR MAY GET VERY HOT DURING NORMAL OPERATION. IF THE BLOWER MOTOR WAS TURNED ON PRIOR TO SERVICING THE BLOWER MOTOR RESISTOR, WAIT FIVE MINUTES TO ALLOW THE BLOWER MOTOR RESISTORS TO COOL BEFORE PERFORMING DIAGNOSIS OR SERVICE. FAILURE TO TAKE THIS PRECAUTION CAN RESULT IN POSSIBLE PERSONAL INJURY. CAUTION: Do not operate the blower motor with the blower motor resistor removed from the circuit. Failure to take this precaution can result in vehicle damage. 1. Disconnect and isolate the negative battery cable. 2. Remove the glove box from the instrument panel. Blower Motor Resistor 3. Disconnect the two wire harness connectors from the front blower motor resistor. 4. Remove the two screws that secure the front blower motor resistor to the front HVAC housing and remove the resistor. INSTALLATION 1. Position the front blower motor resistor into the front HVAC housing. 2. Install the two screws that secure the front blower motor resistor to the front HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.). 3. Connect the two wire connectors to the front blower motor resistor. 4. Install the glove box. 5. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Front > Page 7275 Blower Motor Resistor: Service and Repair Rear REMOVAL WARNING: THE REAR BLOWER MOTOR RESISTOR BLOCK MAY GET VERY HOT DURING NORMAL OPERATION. IF THE BLOWER MOTOR WAS TURNED ON PRIOR TO SERVICING THE BLOWER MOTOR RESISTOR BLOCK, WAIT FIVE MINUTES TO ALLOW THE BLOWER MOTOR RESISTORS TO COOL BEFORE PERFORMING DIAGNOSIS OR SERVICE. FAILURE TO TAKE THIS PRECAUTION CAN RESULT IN PERSONAL INJURY. CAUTION: Do not operate the blower motor with the blower motor resistor block removed from the circuit. Failure to take this precaution can result in vehicle damage. 1. Disconnect and isolate the negative battery cable. 2. Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel. Rear Blower Motor Resistor 3. Disconnect the rear HVAC wire harness connector from the rear blower motor resistor. 4. Remove the two screws that secure the rear blower motor resistor to the rear HVAC housing and remove the resistor. INSTALLATION 1. Position the rear blower motor resistor into the rear HVAC housing. 2. Install the two screws that secure the rear blower motor resistor to the rear HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.). 3. Connect the rear HVAC wire harness connector to the rear blower motor resistor. 4. Reinstall the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel. 5. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations Headliner Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Page 7279 Blower Motor Switch: Diagrams Rear Blower Front Control Switch (3 Zone MTC) Rear Blower Rear Control Switch C1 (3 Zone MTC) Rear Blower Rear Control Switch C2 (3 Zone MTC) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations Cabin Air Filter: Locations Fig.1 Air Filter The Cabin Air Filter access door is located under the instrument panel on the passenger side. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations > Page 7283 Cabin Air Filter: Description and Operation Particulate Air Filter A dust and odor air filter is standard equipment on models equipped with the three zone temperature control systems. The filter element is the same size as the front A/C evaporator to ensure ample filtering capacity. A removable door on the bottom of the front HVAC housing below the glove box provides easy access to the filter element for replacement. The filter should be checked and replaced at least once every 24,000 km (15,000 miles) and checked if heater-A/C system performance seems lower than expected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations > Page 7284 Cabin Air Filter: Service and Repair REMOVAL Air Filter Door - Typical 1. Locate the air filter door on the bottom of the lower front HVAC housing just outboard of the passenger side of the instrument panel center stack. 2. Slide the air filter door latch toward the rear of the vehicle until it engages the opened stop on the door. 3. Pull the air filter door straight downward to disengage it from the air filter opening of the HVAC housing. 4. Use your fingers to reach through the air filter opening of the HVAC housing far enough to grasp the air filter. 5. Pull the air filter straight down and out of the HVAC housing. INSTALLATION NOTE: The particulate air filter is labeled with "Airflow" and an arrow to indicate air flow direction through the filter. This arrow should always be oriented towards the center of the vehicle. Make sure to properly install the particulate air filter. Failure to properly install the filter will result in the need to replace the filter sooner than required by design. 1. Install the filter fully upward into the HVAC housing through the air filter opening with the "Airflow" arrow oriented towards the center of the vehicle. 2. With the latch still positioned against its opened stop, install the air filter door onto the lower HVAC housing air filter opening. 3. Slide the air filter door latch toward the front of the vehicle until it contacts the closed stop on the door. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair REAR QUARTER PANEL / FENDER AIR EXHAUSTER DESCRIPTION Air exhausters, designed to conform to the body structure, allow air entering at the front of the vehicle to flow out the back. By reducing air pressure within the vehicle, the exhausters also reduce blower noise at any given air flow level compared to operating without them and help reduce door closing effort. They are located in the lower rear corners of the body. REMOVAL SHORT WHEELBASE 1. Remove the rear fascia from the body. Refer to Rear Bumper. Fig. 21 2. Using a trim stick or another suitable wide flat bladed tool, carefully pry the air exhauster away from the opening in the lower aperture panel until the snap features release (Fig. 21). 3. Remove the air exhauster from the hole in the lower aperture panel. LONG WHEELBASE NOTE: Models with the optional rear heater and air conditioner do not have an air exhauster on the right side of the vehicle, but have a plastic plug installed in the right lower aperture panel. This plug is removed using the same procedure used to remove the air exhauster from the short wheelbase model. 1. Remove the quarter trim panel from the inside of the left or right quarter inner panel. Refer to Trim Panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and Repair > Page 7288 Fig. 22 2. Using a trim stick or another suitable wide flat bladed tool, carefully pry the air exhauster away from the opening in the lower aperture panel until the snap features release (Fig. 22). 3. Remove the air exhauster from the hole in the lower aperture panel. INSTALLATION SHORT WHEELBASE 1. Position the air exhauster to the hole in the lower aperture panel (Fig. 21). 2. Using hand pressure, press the air exhauster into the opening in the lower aperture panel until the snap features are fully engaged. 3. Reinstall the rear fascia onto the body. LONG WHEELBASE NOTE: Models with the optional rear heater and air conditioner do not have an air exhauster on the right side of the vehicle, but have a plastic plug installed in the right lower aperture panel. This plug is installed using the same procedure used to install the air exhauster onto the short wheelbase model. 1. Position the air exhauster to the hole in the lower aperture panel (Fig. 22). 2. Using hand pressure, press the air exhauster into the opening in the lower aperture panel until the snap features are fully engaged. 3. Reinstall the quarter trim panel onto the inside of the left or right quarter inner panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams A/C Compressor Clutch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Description and Operation Compressor Clutch Coil: Description and Operation A/C Compressor Clutch The A/C compressor clutch assembly consists of a stationary electromagnetic A/C clutch field coil with a zener diode, a pulley bearing and pulley assembly, and a clutch plate. These components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt. The A/C clutch field coil and the pulley bearing and pulley assembly are both retained on the nose of the A/C compressor with snap rings. The clutch plate is splined to the compressor shaft and secured with a bolt. The A/C compressor clutch components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt. When the electromagnetic A/C clutch field coil is energized, it magnetically draws the clutch plate into contact with the clutch pulley and drives the compressor shaft. When the coil is not energized, the pulley freewheels on the clutch hub bearing, which is part of the pulley. A zener diode is connected in parallel with the clutch electromagnetic coil. This diode controls the dissipation of voltage induced into the coil windings by the collapsing of the electromagnetic fields that occurs when the compressor clutch is disengaged. The zener diode dissipates this induced voltage by regulating a current path to ground. This arrangement serves to protect other circuits and components from potentially damaging voltage spikes in the vehicle electrical system that might occur if the voltage induced in the clutch coil windings could not be dissipated. The compressor clutch engagement is controlled by several components: the A/C-heater control in the passenger compartment, the A/C pressure transducer on the liquid line, the evaporator temperature sensor in the HVAC housing for RS models or on the expansion valve for RG models, the powertrain control module (PCM) in the engine compartment, and the compressor clutch relay in the integrated power module (IPM). The PCM may delay compressor clutch engagement for up to thirty seconds. The A/C compressor clutch components cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Compressor Clutch Coil: Initial Inspection and Diagnostic Overview NOTE: The A/C clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley and bearing assembly, or coil replacement. Clutch Plate And Shim(s) Examine the friction surfaces of the clutch pulley and the clutch plate for wear. The pulley and plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft and nose area of the A/C compressor for refrigerant oil. If refrigerant oil is found, the compressor shaft seal is leaking and the A/C compressor must be replaced. Check the clutch pulley bearing for roughness or excessive leakage of grease. Replace the pulley and bearing assembly, if required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7298 Compressor Clutch Coil: Component Tests and General Diagnostics A/C Compressor Clutch Coil The air conditioning compressor clutch coil electrical circuit is controlled by the powertrain control module (PCM) through the A/C compressor clutch relay, which is located in the integrated power module (IPM) in the engine compartment. Begin testing of a suspected compressor clutch coil problem by performing the preliminary checks. PRELIMINARY CHECKS 1. If the compressor clutch will not engage, verify the refrigerant charge level. If the refrigerant charge level is OK, go to Step 2. If the refrigerant charge level is not OK, adjust the refrigerant charge as required. 2. If the A/C compressor clutch still will not engage, disconnect the wire harness connector for the A/C pressure transducer and check for battery current at the connector with the engine running and the A/C-heater control set to the A/C mode. If OK, go to TESTS. If not OK, refer to Body Diagnostic Procedures to perform further diagnosis. TESTS 1. Verify the battery state of charge. 2. Connect an ammeter (0 to 10 ampere scale selected) in series with the clutch coil feed terminal. Connect a voltmeter (0 to 20 volt scale selected) to measure voltage across the battery and the clutch coil. 3. With the heater-A/C control in the A/C mode and the blower at low speed, start the engine and allow it to run at a normal idle speed. 4. The compressor clutch should engage immediately, and the clutch coil voltage should be within two volts of the battery voltage. If the coil voltage is not within two volts of battery voltage, test the clutch coil feed circuit for excessive voltage drop. If the compressor clutch does not engage, refer to Body Diagnostic Procedures to perform further diagnosis. 5. For the acceptable A/C clutch coil current draw specifications refer to Specifications. Specifications apply for a work area temperature of 21° C (70° F). If voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until voltage reads below 12.5 volts. See: Specifications a. If the compressor clutch coil current reading is zero, the coil is open and must be replaced. b. If the compressor clutch coil current reading is four amperes or more, the coil is shorted and must be replaced. A/C Clutch Break-In After a new A/C compressor clutch has been installed, cycle the compressor clutch approximately twenty times (five seconds on, then five seconds off). During this procedure, set the A/C-heater controls to the A/C Recirculation Mode, the blower motor in the highest speed position, and the engine speed at 1500 to 2000 rpm. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher compressor clutch torque capability. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection > Page 7299 Compressor Clutch Coil: Service and Repair REMOVAL NOTE: The compressor clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley, or coil replacement. 1. Disconnect and isolate the negative battery cable. 2. Remove the accessory drive belt. 3. Raise and support the vehicle. 4. Disconnect the engine wire harness connector from the clutch coil connector located on the top of the A/C compressor. 5. On models with the 3.3L and 3.8L engines, disengage the engine wire harness connector retainer from the bracket located on the top of the A/C compressor. 6. On models with the 2.4L, 2.5L and 2.8L engines, remove all of the compressor mounting bolts except the upper left (rear of the A/C compressor), which should only be loosened. Allow the front (pulley end) of the A/C compressor to tilt downward far enough to access the clutch for removal, then tighten the loosened upper left compressor mounting bolt. 7. On models with the 3.3L and 3.8L engines, remove the two bolts and two nuts that secure the A/C compressor to the engine. Disengage the mounting ear at the front of the A/C compressor from the stud on the engine, allow the front (pulley end) of the A/C compressor to tilt downward far enough to access the clutch for removal, then reinstall and tighten the upper left compressor mounting bolt. A/C Compressor Shaft Bolt 8. Remove the compressor shaft bolt. A band-type oil filter wrench or a strap wrench may be used to secure the clutch during bolt removal. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection > Page 7300 Clutch Plate And Shim(s) 9. Tap the clutch plate lightly with a plastic mallet to release it from the splines on the compressor shaft. Remove the clutch plate and shim(s) from the compressor shaft. NOTE: Use care not to lose any of the shim(s). CAUTION: Do not pry between the clutch plate unit and the pulley to remove the clutch plate from the compressor shaft as this may damage the clutch plate. Clutch Pulley Snap Ring 10. Using snap ring pliers (Special Tool C-4574 or equivalent), remove the external snap ring that secures the pulley to the front cover of the A/C Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection > Page 7301 compressor, then slide the pulley off of the compressor. 11. Remove the screw that secures the clutch coil wire lead connector bracket and ground clip to the top of the compressor housing. Remove Clutch Coil Snap Ring 12. Using snap ring pliers (Special Tool C-4574 or equivalent), remove the external snap ring that secures the clutch coil to the front cover of the compressor housing, then slide the clutch coil off of the A/C compressor. INSTALLATION 1. Align the dowel pin on the back of the clutch coil with the hole in the compressor front cover and position the clutch coil onto the A/C compressor. Be certain that the clutch coil pigtail wires are properly oriented and routed so that they are not pinched between the compressor front cover and the clutch coil. NOTE: A new snap ring must be used to secure the clutch coil to the A/C compressor. The bevel side of the snap ring must face outward. 2. Using snap ring pliers (Special Tool C-4574 or equivalent), install the external snap ring that secures the clutch coil to the front cover of the A/C compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or the left of the clutch coil dowel pin location on the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove. CAUTION: If the snap ring is not fully seated in the groove it will vibrate out, resulting in a clutch failure and severe damage to the compressor front cover. 3. Install and securely tighten the screw that secures the clutch coil pigtail wire connector bracket and ground clip to the top of the compressor housing. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection > Page 7302 Clutch Pulley - Installation 4. Install the pulley onto the front cover of the A/C compressor. If necessary, tap the pulley gently with a block of wood placed on the pulley friction surface. CAUTION: Do not mar the friction surfaces of the pulley. NOTE: A new snap ring must be used to secure the clutch pulley to the A/C compressor. The bevel side of the snap ring must face outward. 5. Using snap ring pliers (Special Tool C-4574 or equivalent), install the external snap ring (bevel side facing outward) that secures the clutch pulley to the front cover of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove. 6. If the original clutch plate and clutch pulley are to be reused, reinstall the original shim(s) on the compressor shaft against the shoulder. If a new clutch plate and/or clutch pulley are being used, install a trial stack of shims 2.54 mm (0.010 in.) thick on the compressor shaft against the shoulder. 7. Install the clutch plate onto the compressor shaft. NOTE: The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is still correct. Spin the pulley before performing a final check of the air gap. 8. With the clutch plate assembly tight against the shim(s), measure the air gap between the clutch plate and the pulley face with feeler gauges. The air gap should be between 0.35 - 0.60 mm (0.014 - 0.024 in.). If the proper air gap is not obtained, add or subtract shims as needed until the desired air gap is obtained. 9. Install the compressor shaft bolt. Tighten the bolt to 17.5 N.m (155 in. lbs.). 10. On models with the 2.4L, 2.5L and 2.8L engines, loosely install the four bolts that secure the A/C compressor to the mounting bracket on the engine (2.4L), or the cylinder block (2.5L/2.8L). Tighten the bolts to 28 N.m (21 ft. lbs.). 11. On models with the 3.3L and 3.8L engines, loosely install the two bolts and two nuts that secure the A/C compressor to the engine. Tighten each of the fasteners to 54 N.m (40 ft. lbs.) using the following sequence: The upper nut at the front of the compressor. - The lower nut at the front of the compressor. - The upper bolt at the rear of the compressor. - The lower bolt at the rear of the compressor. 12. On models with the 3.3L and 3.8L engines, engage the retainer on the engine wire harness compressor clutch coil take out with the bracket on the top of the A/C compressor. 13. Connect the engine wire harness connector to the A/C compressor clutch coil. 14. Install the accessory drive belt. 15. Lower the vehicle. 16. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7306 Compressor Clutch Relay: Diagrams 8w-10-3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7307 8w-10-5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7308 A/C Compressor Clutch Relay 2002-06 Mini Vans A/C Compressor Clutch 2003 Voyager, Caravan Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7309 Compressor Clutch Relay: Description and Operation A/C Compressor Clutch Relay The A/C clutch relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The A/C clutch relay is located in the integrated power module (IPM) in the engine compartment. The ISO-standard A/C clutch micro-relay is an electromechanical switch that uses a low current input controlled by the powertrain control module (PCM) to control the high current output to the A/C clutch field coil. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the A/C clutch field coil. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The A/C clutch relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the A/C compressor clutch relay include: - The common feed terminal (30) receives a battery current input from a fuse in the IPM through a fused B(+) circuit at all times. - The coil ground terminal (85) receives a ground input from the PCM through the compressor clutch relay control circuit only when the PCM electronically pulls the control circuit to ground. - The coil battery terminal (86) receives a battery current input from the PCM through a fused ignition switch output (run-start) circuit only when the ignition switch is in the On or Start positions. - The normally open terminal (87) provides a battery current output to the compressor clutch coil through the compressor clutch relay output circuit only when the compressor clutch relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the compressor clutch relay coil is de-energized. The A/C clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard micro-relay and for complete HVAC wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 7310 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. A/C Compressor Clutch Relay 2. Remove the cover from the integrated power module (IPM) located in the engine compartment. NOTE: Refer to the fuse and relay map on the inside of the IPM cover for A/C compressor clutch relay location. 3. Remove the A/C compressor clutch relay from the IPM. INSTALLATION NOTE: Refer to the fuse and relay map on the inside of the integrated power module (IPM) cover for A/C compressor clutch relay location. 1. Position the A/C compressor clutch relay into the receptacle in the IPM. 2. Align the A/C compressor clutch relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 24-015-05 > Aug > 05 > A/C - Condenser Stone/Road Debris Damage Condenser HVAC: Customer Interest A/C - Condenser Stone/Road Debris Damage NUMBER: 24-015-05 GROUP: Heating & Air Conditioning DATE: August 18, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL AUGUST 30, 2005. SUBJECT: A/C Condenser Guard Installation OVERVIEW: This bulletin involves adding a condenser guard to the front of the vehicle. MODELS: 2005 (RS) Town & Country/Caravan DISCUSSION: The A/C condenser may become damaged due to rocks and/or road debris impacting the condenser. A new A/C condenser guard is now available to reduce or eliminate the A/C condenser damage caused by rocks and/or road debris. If the A/C condenser is being replaced for any reason the A/C condenser guard should be added to protect the A/C condenser from future damage. If the technician notices the vehicle is not equipped with an A/C condenser guard, the A/C condenser guard should be added to protect the A/C condenser from future damage. PARTS REQUIRED REPAIR PROCEDURE: 1. Remove the front fascia. Refer to the detailed removal procedures available in TechCONNECT, under: Service Info, 13 - Frame & Bumpers/Bumpers/Front Fascia - Removal. 2. Remove the screw holding the ambient temperature sensor to the radiator closure panel and unplug the electrical connector from the sensor. 3. Release the two wiring harness anchors closest to the ambient temperature sensor. 4. Remove the fasteners from the lower A/C condenser seal. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Customer Interest for Condenser HVAC: > 24-015-05 > Aug > 05 > A/C - Condenser Stone/Road Debris Damage > Page 7319 5. Install the condenser guard, included in the kit, over the top of the lower A/C condenser seal and install the lower A/C condenser seal screws through the condenser guard and lower seal into the lower cross member. Install the additional screw supplied in the kit. This will locate the condenser guard (Fig. 1). 6. Hold the condenser guard up against the bottom of the bumper beam as a template for the bumper beam mounting holes. Mark the location of the three holes with a center punch and drill three (3) 6.75 mm (17/64 in.) holes in the beam. Apply a small amount of Corrosion Inhibitor, p/n 82300508 to each hole, and install three (3) push pins, included in the kit. 7. Install the two temperature sensor wire harness fasteners. 8. Install the temperature sensor bracket and remaining wire harness fastener(s). 9. Install the front fascia. Refer to the detailed installation procedures available in TechCONNECT, under: Service Info, 13 - Frame & Bumpers/Bumpers/Front Fascia - Installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 24-015-05 > Aug > 05 > A/C - Condenser Stone/Road Debris Damage Condenser HVAC: All Technical Service Bulletins A/C - Condenser Stone/Road Debris Damage NUMBER: 24-015-05 GROUP: Heating & Air Conditioning DATE: August 18, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL AUGUST 30, 2005. SUBJECT: A/C Condenser Guard Installation OVERVIEW: This bulletin involves adding a condenser guard to the front of the vehicle. MODELS: 2005 (RS) Town & Country/Caravan DISCUSSION: The A/C condenser may become damaged due to rocks and/or road debris impacting the condenser. A new A/C condenser guard is now available to reduce or eliminate the A/C condenser damage caused by rocks and/or road debris. If the A/C condenser is being replaced for any reason the A/C condenser guard should be added to protect the A/C condenser from future damage. If the technician notices the vehicle is not equipped with an A/C condenser guard, the A/C condenser guard should be added to protect the A/C condenser from future damage. PARTS REQUIRED REPAIR PROCEDURE: 1. Remove the front fascia. Refer to the detailed removal procedures available in TechCONNECT, under: Service Info, 13 - Frame & Bumpers/Bumpers/Front Fascia - Removal. 2. Remove the screw holding the ambient temperature sensor to the radiator closure panel and unplug the electrical connector from the sensor. 3. Release the two wiring harness anchors closest to the ambient temperature sensor. 4. Remove the fasteners from the lower A/C condenser seal. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Condenser HVAC: > 24-015-05 > Aug > 05 > A/C - Condenser Stone/Road Debris Damage > Page 7325 5. Install the condenser guard, included in the kit, over the top of the lower A/C condenser seal and install the lower A/C condenser seal screws through the condenser guard and lower seal into the lower cross member. Install the additional screw supplied in the kit. This will locate the condenser guard (Fig. 1). 6. Hold the condenser guard up against the bottom of the bumper beam as a template for the bumper beam mounting holes. Mark the location of the three holes with a center punch and drill three (3) 6.75 mm (17/64 in.) holes in the beam. Apply a small amount of Corrosion Inhibitor, p/n 82300508 to each hole, and install three (3) push pins, included in the kit. 7. Install the two temperature sensor wire harness fasteners. 8. Install the temperature sensor bracket and remaining wire harness fastener(s). 9. Install the front fascia. Refer to the detailed installation procedures available in TechCONNECT, under: Service Info, 13 - Frame & Bumpers/Bumpers/Front Fascia - Installation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 7326 Condenser HVAC: Description and Operation A/C Condenser - 2.4L/3.3L/3.8L Engines The A/C condenser is located in the front of the engine compartment behind the front fascia. The A/C condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the A/C compressor to give up its heat to the air passing over the condenser fins, which causes the refrigerant to cool and change to a liquid state. The A/C condenser may be removed for service without removing the radiator and cooling fan from the vehicle. The A/C condenser for vehicles equipped with the 2.4L, 3.3L and 3.8L engines are equipped with an integral automatic transmission cooler and tapping block. This design is referred to as a combination cooler. When air passes through the fins of the A/C condenser, the high-pressure refrigerant gas within the A/C condenser gives up its heat. The refrigerant then condenses as it leaves the A/C condenser and becomes a high-pressure liquid. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the A/C system. Therefore, it is important that there are no objects placed in front of the radiator grille openings at the front of the vehicle or foreign material on the condenser fins that might obstruct proper air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or A/C condenser service. The A/C condenser cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 7327 Condenser HVAC: Service and Repair REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: Before removing the A/C condenser, note the location of each of the radiator and condenser air seals. These air seals are used to direct air through the A/C condenser and radiator. The air seals must be reinstalled in their proper locations in order for the A/C and engine cooling systems to perform as designed. 1. Recover the refrigerant from the refrigerant system. 2. Remove the front fascia. NOTE: It is not necessary to remove the quick-connect fittings from the transmission oil cooler tapping block when disconnecting the transmission oil cooler lines from the cooler. A/C Condenser - Left Hand View 3. Disconnect the transmission oil cooler lines from the quick-connect fittings located on the transmission oil cooler tapping block on the left side of the A/C condenser (combination cooler). 4. Disconnect the A/C discharge line and the A/C liquid line from the right side of the A/C condenser. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 7328 A/C Condenser - Right Hand View 5. Install plugs in, or tape over the opened A/C discharge and liquid line fittings and the condenser ports. 6. Disengage the retaining clips that secure the upper A/C condenser mounting brackets to the radiator. 7. Lift the A/C condenser (combination cooler) straight up to disengage the lower mounting brackets from the radiator and carefully remove the condenser from the engine compartment. INSTALLATION NOTE: - If the A/C condenser is being replaced, add 50 milliliters (1.7 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. - Be certain that each of the radiator and condenser air seals are reinstalled in their proper locations. These air seals are required for proper A/C and engine cooling system operation. 1. Position the A/C condenser (combination cooler) into the engine compartment. 2. Carefully lower the A/C condenser straight down to engage the lower mounting brackets to the radiator. 3. Engage the upper A/C condenser mounting brackets to the radiator. Be sure that the upper retaining clips are fully engaged to the upper mounting brackets. 4. Remove the tape or plugs from the opened refrigerant line fittings and the condenser ports. 5. Connect the A/C discharge line and the A/C liquid line to the A/C condenser. 6. Connect the transmission oil cooler lines to the quick-connect fittings located on the transmission cooler tapping block. Be sure that the quick-connect fittings are fully engaged to the lines. 7. Install the front fascia. 8. Evacuate the refrigerant system. 9. Charge the refrigerant system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations Control Assembly: Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 7332 Center Instrument Panel Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Page 7333 Headliner Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Connector Views Control Assembly: Connector Views A/C - Heater Control C1(MTC) A/C - Heater Control C2 (MTC) Auto Temp Control C1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Connector Views > Page 7336 Auto Temp Control C2 Auto Temp Control C3 Rear A/C-Heater Unit (3 Zone MTC) Rear Auto Temp Control Switch (3 Zone ATC) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front Control Assembly: Description and Operation Front A/C-HEATER CONTROL The front A/C-heater control is located at the center of the instrument panel and uses electrical controls. These controls provide the vehicle operator with a number of setting options to help control the climate and comfort within the vehicle. The front A/C-heater control for the single zone heating-A/C system allows one temperature setting for the entire vehicle, while the dual zone heating-A/C system allows both the driver and the front seat passenger the ability to individually regulate air temperature for their side of the vehicle. All controls are identified by ISO graphic symbols. The front A/C-heater control module must be recalibrated each time an actuator motor or the A/Cheater control is replaced. The A/C-heater control cannot be repaired. If faulty or damaged, the entire unit must be replaced. The control knobs are available for service replacement. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front > Page 7339 Control Assembly: Description and Operation Rear The rear heating-A/C system is controlled by temperature controls that are centrally mounted directly into the headliner, or if equipped with the available DVD player, located in a housing mounted to the overhead rails. The rear A/C-heater control allows selection of three blower motor speeds and an Off position when the center knob on the front A/Cheater control is set to the Rear position, otherwise the front A/C-heater control operates both front and rear heater-A/C operation. With the rear A/C-heater control active, temperature selection dictates the air distribution mode (floor or overhead air) of the rear heater-A/C unit. A cool temperature setting directs flow to the overhead outlets and a warm temperature setting to the floor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C Heater Control Calibration - Front Control Assembly: Service and Repair A/C Heater Control Calibration - Front The A/C-heater control module must be recalibrated each time an actuator motor or the A/C-heater control is replaced. If the vehicle is so equipped, the calibration procedure also includes rear HVAC positions for each actuator motor. 1. Turn the ignition switch to the On position. 2. If equipped with the manual temperature control (MTC) system, press and hold the Rear Wipe/ Wash and Recirculation buttons for at least five seconds. If equipped with the automatic temperature control (ATC) system, simultaneously press and hold the Power and Recirculation buttons on the A/Cheater control for at least five seconds. The MTC A/C-heater control Rear Wipe/Wash button light emitting diode (LED) and Recirculation button LED, or the ATC A/C-heater control Delay and Recirculation graphics will begin to flash when the calibration procedure has begun. 3. The calibration procedure should take less than two minutes to complete for the manual A/C-heater control, and less than twenty seconds for the ATC A/C-heater control. When the LEDs or graphics stop flashing, the calibration procedure is complete. 4. If the LEDs or graphics continue to flash beyond the two minute (manual) or twenty second (ATC) calibration time, it indicates that the A/Cheater control has detected a failure and a Diagnostic Trouble Code (DTC) has been set. The LEDs or graphics will continue to flash even after the ignition switch is cycled Off and On, until a successful calibration is completed or until the vehicle has been driven about 13 kilometers (8 miles). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C Heater Control Calibration - Front > Page 7342 Control Assembly: Service and Repair Front REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel from the instrument panel and place it on a workbench. A/C Heater Control - ATC Shown, MTC Typical 3. If the vehicle is equipped with the automatic temperature control (ATC) heating-A/C system, disconnect the infrared sensor connector from the back of the A/C-heater control. 4. Remove the six screws that secure the A/Cheater control to the back of the instrument panel center bezel and remove the control. INSTALLATION 1. Position the A/C-heater control into the instrument panel center bezel. 2. Install the six screws that secure the A/Cheater control to the instrument panel center bezel. Tighten the screws to 2 N.m (17 in. lbs.). 3. If the vehicle is equipped with the ATC heating-A/C system, connect the infrared sensor connector to A/C-heater control. 4. Install the center bezel onto the instrument panel. 5. Reconnect the negative battery cable and calibrate the A/C-heater control. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C Heater Control Calibration - Front > Page 7343 Control Assembly: Service and Repair Rear REMOVAL OVERHEAD RAIL MOUNTED 1. Disconnect and isolate the negative battery cable. Rear A/C - Heater Control - MTC System Shown 2. Using a trim stick C-4755 or equivalent, gently pry the rear A/C-heater control housing off of the overhead rails. 3. Remove the rear A/C-heater control and housing assembly from the overhead rails and disconnect the wire harness connector(s) from the back of the control. Rear A/C - Heater Control Housing - MTC System Shown 4. If required, remove the three screws that secure the rear A/C-heater control to the housing and remove the control from the housing. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C Heater Control Calibration - Front > Page 7344 HEADLINER MOUNTED 1. Disconnect and isolate the negative battery cable. Rear A/C - Heater Control - ATC System Shown 2. Using a trim stick C-4755 or equivalent, gently pry the top edge of the control bezel away from the headliner to release the two retaining clips. 3. Remove the rear A/C-heater control and bezel assembly from the headliner and disconnect the wire harness connector(s) from the back of the control. Rear A/C - Heater Control Bezel - ATC System Shown 4. If required, remove the three screws that secure the rear A/C-heater control to the bezel and remove the control from the bezel. INSTALLATION 1. If required, position the rear A/C-heater control onto the rear A/C- heater control housing or bezel (depending on application). 2. Install the three screws that secure the rear A/C-heater control to the housing or bezel. Tighten the screws to 2 N.m (17 in. lbs.). 3. Position the rear A/C-heater control to the headliner or overhead rail (depending on application) and connect the wire harness connector(s) to the rear of the control. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C Heater Control Calibration - Front > Page 7345 4. If headliner mounted, insert the locator tabs on the back of the rear A/C-heater control bezel over the forward edge of the opening in the headliner and using hand pressure, push the rear A/C-heater control bezel into the headliner until the two retaining clips fully seat. 5. If overhead rail mounted, position the top of the rear A/C-heater control housing over the overhead rails and using hand pressure, push the rear A/C-heater control housing onto the overhead rails until the retaining clips fully seat. 6. Reconnect the negative battery cable. 7. Using the DRB-III(R) scan tool, reset the Rear Temperature Selector calibration values. 8. Verify that the Actuator Calibration of the Front Control has passed. If an Actuator Calibration has not passed correct any errors before proceeding further. 9. Rotate the Rear Temperature Selector counter clockwise to the Cold Position, allow the Selector to remain in the Cold Position for 5 seconds. 10. Rotate the Rear Temperature Selector Clockwise to the Hot Position, allow the Selector to remain in the Cold Position for 5 seconds. 11. Calibration is now complete. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams Control Module HVAC: Diagrams Front Blower Module C1 (ATC) Front Blower Module C2 (ATC) Rear Blower Motor Power Module C1 (3 Zone ATC) Rear Blower Motor Power Module C2 (3 Zone ATC) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Front Control Module HVAC: Description and Operation Front Front Blower Power Module A front blower motor power module is used on this model when it is equipped with the automatic temperature control (ATC) heating-A/C system. Models equipped with the manual temperature control (MTC) heating-A/C system use a blower motor resistor, instead of the blower motor power module. The front blower motor power module is mounted to the rear of the front HVAC housing, directly behind the glove box. The blower motor power module consists of a molded plastic mounting plate with two integral connector receptacles (1). Concealed behind the mounting plate is the power module electronic circuitry and a large finned heat sink (2). The front blower motor power module is accessed for service by removing the glove box. The front blower motor power module is connected to the vehicle electrical system through a dedicated lead and connector of the front HVAC wire harness. A second connector receptacle receives the wire harness connector from the front blower motor. The front blower motor power module allows the microprocessor-based automatic temperature control (ATC) A/Cheater control to calculate and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a pulse width modulated (PWM) circuit strategy. The PWM voltage is applied to a comparator circuit which compares the PWM signal voltage to the front blower motor feedback voltage. The resulting output drives the power module circuitry, which provides a linear output voltage to change or maintain the desired blower speed. The front blower motor power module is diagnosed using a DRBIII(R) scan tool. The front blower motor power module cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Front > Page 7351 Control Module HVAC: Description and Operation Rear Rear Blower Motor Power Module A rear blower motor power module is used on this model when it is equipped with the automatic temperature control (ATC) heating-A/C system.Models equipped with the manual temperature control (MTC) heating-A/C system use a blower motor resistor, instead of the blower motor power module. The rear blower motor power module is installed in the back of the rear HVAC housing, directly above the A/C expansion valve. The power module consists of a molded plastic mounting plate with two integral connector receptacles. Concealed behind the mounting plate is the power module electronic circuitry and a large finned heat sink. The rear blower motor power module is accessed for service by removing the right quarter and D-pillar trim panels. The rear blower motor power module is connected to the vehicle electrical system through a dedicated lead and connector of the rear HVAC wire harness. A second connector receptacle receives the wire harness connector from the rear blower motor. The rear blower motor power module allows the microprocessor-based automatic temperature control (ATC) A/Cheater control to calculate and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a pulse width modulated (PWM) circuit strategy. The PWM voltage is applied to a comparator circuit which compares the PWM signal voltage to the rear blower motor feedback voltage. The resulting output drives the power module circuitry, which adjusts the voltage output received from the rear blower motor relay to change or maintain the desired blower speed. The rear blower motor power module is diagnosed using a DRBIII(R) scan tool. The rear blower motor power module cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module Control Module HVAC: Service and Repair Front Blower Motor Power Module REMOVAL WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. - THE HEAT SINK FOR THE BLOWER MOTOR POWER MODULE MAY GET VERY HOT DURING NORMAL OPERATION. IF THE BLOWER MOTOR WAS TURNED ON PRIOR TO SERVICING THE BLOWER MOTOR POWER MODULE, WAIT FIVE MINUTES TO ALLOW THE HEAT SINK TO COOL BEFORE PERFORMING DIAGNOSIS OR SERVICE. FAILURE TO TAKE THIS PRECAUTION CAN RESULT IN POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the negative battery cable. 2. Remove the glove box from the instrument panel. 3. Disconnect the two wire harness connectors from the front blower motor power module. Front Blower Motor Power Module 4. Remove the two screws that secure the front blower motor power module to the front HVAC housing and remove the power module. INSTALLATION 1. Position the front blower motor power module into the front HVAC housing. 2. Install the two screws that secure the front blower motor power module to the front HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.). 3. Connect the two wire connectors to the front blower motor power module. 4. Install the glove box. 5. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module > Page 7354 Control Module HVAC: Service and Repair Rear Blower Motor Power Module REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel. Rear Blower Motor Power Module 3. Disconnect the rear HVAC wire harness connector from the rear blower motor power module. 4. Disconnect the rear blower motor wire harness connector from the rear blower motor power module. 5. Remove the two screws that secure the rear blower motor power module to the rear HVAC housing and remove the power module. INSTALLATION 1. Position the rear blower motor power module into the rear HVAC housing. 2. Install the two screws that secure the rear blower motor power module to the rear HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.). 3. Connect the rear blower motor wire harness to the rear blower motor power module. 4. Connect the rear HVAC wire harness connector to the rear blower motor power module. 5. Install the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel. 6. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7363 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7364 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7365 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7366 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7367 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7368 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7369 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7370 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7371 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7372 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7373 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7374 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid Technical Service Bulletin # 24-006-06 Date: 060810 A/C - Musty Odors When Hot/Humid NUMBER: 24-006-06 GROUP: Heating & A/C DATE: Approval Pending THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-013-05, DATED AUGUST 4, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE AN ADDITIONAL MODEL, YEAR AND REVISED AB/CS/LX/RS/WK/XK REPAIR PROCEDURE. SUBJECT: A/C Cooling Coil Odor OVERVIEW: This bulletin involves inspecting for leaves and other foreign material, cleaning, and treating the cooling coil and housing. MODELS: 1995-2003 (AB) Ram Van/Wagon 1995-2004 (AN) Dakota 2004 - **2007** (CS) Pacifica 1998 - 2003 (DN) Durango 2002 - **2007** (DR/DH/D1) Ram Pickup 2004 - **2007** (HB) Durango 2001 - 2006 (JR) Sebring Convertible/Sebring Sedan/Stratus Sedan 2002 - **2007** (KJ) Liberty 1993 - 2004 (LH) 300M/Concorde/LHS/New Yorker/Intrepid/Vision 2005 - **2007** (LX) 300/**Charger**/Magnum 2005 - **2007** (ND) Dakota 2002 (PG) PT Cruiser (International Markets) 1995 - 2005 (PL) Neon/SX 2.0 2001 - **2007** (PT) Chrysler PT Cruiser 2001 - **2007** (RG) Chrysler Voyager (International Markets) 2001 - **2007** (RS) Town & Country/Caravan/Voyager 2001 - 2005 (ST) Sebring Coupe/Stratus Coupe 1997 - 2006 (TJ) Wrangler 2002 - 2006 (VA) Sprinter 1999 - 2004 (WJ/WG) Grand Cherokee 2005 - **2007** (WK/WH) Grand Cherokee 2006 - **2007** (XK**/XH)** Commander SYMPTOM/CONDITION: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7380 Some vehicle operators may experience a musty odor from the A/C system, primarily at start up in hot and humid climates. This odor may be the result of microbial growth on the cooling coil. During normal A/C system operation, condensation forms in and around the NC cooling coil. When airborne pollutants mix with this condensation, bacteria and fungi growth begins and odor results. DIAGNOSIS: If the operator describes, or the technician experiences a musty odor when operating the A/C system, perform the appropriate Repair Procedure based on the vehicle model. PARTS REQUIRED: A/C COOLING COIL CLEANER REQUIREMENTS BY VEHICLE MODEL EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7381 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. AB/CS/LX/RS/WK/XK Vehicle Procedure 1. Open the hood. 2. On LX/RS/**2005 WK/WH (2006 - 2007 WH/WK/XH/XK vehicles skip to step 8) (AB/CS** vehicles proceed to next step), raise the vehicle on a suitable hoist. 3. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 4. On **2005 WK/WH** vehicles (other vehicles proceed to next step), fabricate the cooling coil drain plug as follows (Fig. 1): a. Gather a 457.2 mm (18 in.) long, 9.8 mm (3/8 in.) drive socket extension; a deep 12 mm, 9.8 mm (3/8 in.) drive socket, and a 152.4 mm (6 in.) piece of 15.9 mm (5/8 in.) ID heater hose, p/n HHR00058AA b. Place the socket on the end of the extension. Slide approximately 25.4 mm (1 in.) of the heater hose over the socket. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7382 c. Slip the heater hose over the cooling coil drain tube, located above the right side of the transmission using the socket and extension to reach up between the frame and the exhaust. Leave the hose socket and extension in place (Fig. 2). Proceed to Step # 7. 5. Cap/clamp off the drain tube using a suitable cap/clamp. 6. AB vehicles proceed to Step # 12, other vehicles proceed to next step. 7. On LX/RS/**2005 WK/WH** vehicles (other vehicles proceed to next step), lower the vehicle. 8. Remove passenger side floor mat. 9. Place a protective cover over the carpet and the passenger front seat. 10. On LX/RS/**WH/WK/XH**XK vehicles (other vehicles proceed to next step), remove the glove box to gain access to the blower motor resistor /power module. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Glove Box 11. On LX/**WH/WK/XH/XK vehicles, remove the passenger side instrument panel silencer. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, Instrument Panel, Instrument Panel Silencer. On 2006 - 2007 WH/WK/XH/XK vehicles remove the blower motor and use a shop vacuum to clean the evaporator coil, reinstall the blower motor and skip to step 18. Other vehicles proceed to next step.** 12. Remove the 2 screws securing the blower motor resistor/power module in the NC housing and remove the blower motor resistor/power module. Do not disconnect the electrical connector. 13. On LX/**2005 WK/WH** vehicles (other vehicles proceed to next step), proceed to Step # 18 14. If the vehicle is not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, remove the A/C air filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. If not equipped with an A/C air filter, proceed to next step. If equipped with an A/C air filter, install the air filter door (do not install the air filter at this time). 18. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7383 19. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 20. Connect the assembled applicator tool to the shop compressed air supply line. 21. Insert the applicator tool into the blower resistor/power module opening. 22. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 23. Allow the vehicle sit for a minimum of 30 minutes. 24. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 27. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 25. Remove the cap/clamp from the drain tube. 26. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 27. Fill each empty cleaner bottle with normal tap water. 28. One at a time, screw each bottle of water onto the applicator tool. 29. Insert the applicator tool into the blower resistor opening. 30. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 31. Install the blower motor resistor/power module. 32. Start the engine. 33. Raise all the windows to a slightly open position (about 1/2 inch opening). 34. Set the blower to HIGH. 35. Set the A/C switch to A/C OFF. 36. Set mode switch to PANEL OUTLETS. 37. Set temperature switch to FULL HEAT. 38. Set recirculation switch to RECIRCULATE. 39. Allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the OFF position. 41. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 44. Other vehicles proceed to next step.** 42. Cap/clamp off the drain tube using a suitable cap. 43. On LX/RS/**2005 WH/WK/** vehicles (other vehicles proceed to next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 44. Open all windows in the vehicle. 45. Remove the blower motor resistor/power module. 46. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7384 47. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 48. Allow the vehicle to sit for 30 minutes. 49. Install the blower motor resistor/power module. 50. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 53. Other vehicles proceed to next step.** CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 51. Remove the drain tube cap/clamp. 52. On LX/RS/**2005 WH/WK** vehicles (other vehicles proceed to next step), lower the vehicle. 53. Start the engine. 54. Raise all the windows to a slightly open position (about 1/2 inch opening). 55. Set the blower to HIGH. 56. Set the A/C switch to A/C OFF. 57. Set mode switch to PANEL OUTLETS. 58. Set temperature switch to FULL HEAT. 59. Set recirculation switch to RECIRCULATE. 60. Allow the engine to run for 20 minutes. 61. Turn the ignition switch to the OFF position. 62. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 63. On LX/RS/**2005 WH/WK vehicles, raise the vehicle on a suitable hoist. On 2006 - 2007 WH/WK/XH/XK skip to step 67. Other vehicles proceed to next step.** CAUTION: In the following step be careful not to damage the A/C cooling coil. 64. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 65. AB vehicles proceed to Step # 72, CS vehicles proceed to Step # 68, LX/RS/**2005 WH/WK** vehicles proceed to Step # 66. 66. Lower the vehicle. 67. On **LX/WH/WK/XH/XK** vehicles (RS vehicles proceed to next step), install the right silencer pad. 68. Install the glove box. 69. If the vehicle is not equipped with an A/C air filter, proceed to the next step. If equipped with an A/C filter, remove the air filter door and install the A/C air filter. Replace with a new filter, if necessary. See the parts table for the appropriate part number filter. 70. Remove the carpet and seat protector. 71. Install the floor mat. 72. Close the hood. AN/DN/DR/HB/JR/KJ/LH/ND/PL/PT/TJ/WG/WJ Vehicles Procedure Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7385 1. Open the hood. 2. Disconnect and isolate the negative battery cable. 3. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle on a suitable hoist. 4. On AN/DN/ND - vehicles (other vehicles proceed to the next step), remove the exhaust heat shield covering the cooling coil housing drain. 5. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 6. On AN/DN/DR/HB/KJ vehicles (other vehicles proceed to next step), cap off the drain tube using a suitable cap. When the drain tube is capped off, proceed to Step # 9. 7. On ND vehicles (other vehicles proceed to next step), plug the cooling coil drain using a piece of plastic or a shop towel. When the drain tube is plugged, proceed to Step #9. 8. Clamp off the drain tube. 9. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 10. Remove passenger side floor mat. 11. Place a protective cover over the carpet and the passenger front seat. 12. If applicable, remove the silencer pad from under the instrument panel on the right side to gain access to the blower motor. 13. On LH vehicles (other vehicles proceed to next step), remove the lower right under panel duct and blower motor cover. 14. Disconnect the blower motor wire harness connector and remove the blower motor. 15. Inspect and remove any leaves and debris. 16. If necessary, use a shop vacuum to clean the cooling coil. 17. Open all the windows in the vehicle. NOTE: Technician must use eye protection, rubber gloves, and protective clothing. NOTE: No occupants should be in the vehicle during material application. 18. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 19. Connect the assembled applicator tool to the shop compressed air supply line. 20. Insert the applicator tool into the blower motor opening. Spray all of the cooling coil cleaner onto the cooling coil until the required number of bottles are empty (See table for required number of bottles). 21. Allow the vehicle to sit for a minimum of 30 minutes. 22. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 23. Remove the drain tube clamp/cap/plug. 24. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 25. Fill each empty cleaner bottle with normal tap water. 26. One at a time, screw each bottle of normal tap water onto the applicator tool. 27. Spray all of the normal tap water onto the cooling coil until each bottle is empty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7386 28. Install the blower motor and connect the blower motor wire harness connector. 29. Connect the negative battery cable. 30. Start the engine. 31. Raise all the windows to a slightly open position (about 1/2 inch opening). 32. Set the blower to HIGH - A/C OFF. 33. Set mode switch to PANEL OUTLETS. 34. Set temperature switch to FULL HEAT. 35. Set recirculation switch to RECIRCULATE. 36. With the engine running, allow the blower to operate for 20 minutes. 37. Turn the ignition switch to the OFF position. 38. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. 39. Install the drain tube clamp/cap/plug. 40. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 41. Open all the windows in the vehicle. 42. Disconnect and isolate the negative battery cable. 43. Disconnect the blower motor wire harness connector and remove the blower motor. 44. Shake an 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 45. Insert the applicator tool into the blower motor opening. Spray the full contents of the bottle on the cooling coil being carefully to cover the entire surface of the cooling coil. 46. Allow the vehicle to sit for 30 minutes. 47. Install the blower motor and connect the blower motor wire harness connector. 48. Connect the negative battery cable. 49. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 50. Remove the drain tube clamp/cap. 51. On AN/DN/HB/JR/LH/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 52. Start the engine. 53. Raise all the windows to a slightly open position (about 1/2 inch opening). 54. Set the blower to HIGH - A/C OFF. 55. Set mode switch to PANEL OUTLETS. 56. Set temperature switch to FULL HEAT. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7387 57. Set recirculation switch to RECIRCULATE. 58. With the engine running, allow the blower to operate for 20 minutes. 59. Turn the ignition switch to the OFF position. 60. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 61. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), raise the vehicle. CAUTION: In the following step be careful not to damage the A/C cooling coil. 62. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 63. On AN/DN/ND - vehicles (other vehicles proceed to the next step), install the exhaust heat shield covering the cooling coil housing drain. 64. On AN/DN/HB/JR/LH/ND/PT/WG/WJ - vehicles (other vehicles proceed to the next step), lower the vehicle. 65. On LH vehicles (other vehicles proceed to next step), install the blower motor cover and lower right under panel duct. 66. Remove the carpet and seat protector. 67. If applicable, install the silencer pad under the right side of the instrument panel. 68. Install floor mat. 69. Close the hood. ST Vehicle Procedure 1. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 2. Remove passenger side floor mat. 3. Place a protective cover over the carpet and the passenger front seat. 4. Remove the joint duct. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Blower Assembly and Resistor, Joint Duct. 5. Inspect and remove any leaves and debris. 6. If necessary, use a shop vacuum to clean the cooling coil. NOTE: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 7. Screw the bottle of cooling coil cleaner (p/n 05170022AA) onto the applicator tool. 8. Connect the assembled applicator tool to the shop compressed air supply line. 9. Insert the applicator tool into the opening created by the joint duct removal. 10. Spray the full contents of 2 bottles of cooling coil cleaner onto the evaporator, moving the tool so that the evaporator is completely covered, until both bottles are empty (16 oz. total). 11. Allow the vehicle to sit for a minimum of 30 minutes. 12. Fill both of the empty cooling coil cleaner bottles with normal tap water. 13. Screw one bottle of water onto the applicator tool. 14. Insert the applicator tool into the opening of the heater/cooler unit at the evaporator. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7388 15. Spray the full contents of water until the bottle is empty. 16. Repeat Step #13 through Step #15 using the second bottle of water. When both bottles of water are empty, proceed to the next step. 17. Install the joint duct. 18. Disconnect the A/C clutch electrical connector at the A/C compressor. 19. Start the engine. 20. Set the blower to HIGH - A/C OFF. 21. Set mode switch to PANEL OUTLETS. 22. Set temperature switch to FULL HEAT. 23. Set recirculation switch to RECIRCULATE. 24. Open windows slightly (about 1/2 inch opening). 25. With the engine running, allow the blower to operate for 20 minutes. 26. Turn the engine off. 27. Turn the ignition switch ON, do not start the engine, to allow blower motor operation. 28. Fully open all windows. 29. Remove the outer glove box and the inner glove box. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body, 23C Body Interior, Instrument Panel CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 30. Shake the 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 31. Insert the applicator tool into the recirculation inlet (behind glove box opening). Spray the full contents of the bottle in the airstream until the bottle is empty. 32. Start the engine. 33. Set the blower to HIGH. 34. Set the A/C switch to A/C OFF. 35. Set mode switch to PANEL OUTLETS. 36. Set temperature switch to FULL HEAT. 37. Set recirculation switch to RECIRCULATE. 38. Open windows slightly (about 1/2 inch opening). 39. With the engine running, allow the blower to operate for 20 minutes. 40. Turn the ignition switch to the off position. 41. Fill the 4 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 42. Connect the A/C compressor clutch electrical connector at the compressor. 43. Open the right side panel outlet vent. 44. Install inner glove box. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7389 45. Install outer glove box. 46. Remove the carpet and seat protector. 47. Install floor mat. VA Vehicle Procedure 1. Raise the vehicle on a suitable hoist. 2. Inspect the cooling coil housing drain for leaves or other foreign material that may be blocking the drain. 3. Clamp off the drain tube using a suitable clamp. 4. Lower the vehicle. 5. Remove the HVAC filter cover and HVAC filter. Refer to the detailed service information available in TechCONNECT, under: Service Info, 24 - Heating & Air Conditioning, Distribution, Air Filter. 6. Inspect and remove any leaves and debris. 7. If necessary, use a shop vacuum to clean the cooling coil. 8. Open all the windows in the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 9. Screw the bottle of cooling coil cleaner (pin 05170022AA) onto the applicator tool. 10. Connect the assembled applicator tool to the shop compressed air supply line. 11. Insert the applicator tool into the HVAC filter opening. 12. Spray all of the cooling coil cleaner onto the cooling coil continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered until the required number of bottles are empty (See table for required number of bottles). 13. Allow the vehicle sit for a minimum of 30 minutes. 14. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 15. Remove the clamp from the drain tube. 16. Lower the vehicle. 17. Fill each empty cleaner bottle with normal tap water. 18. One at a time, screw each bottle of water onto the applicator tool. 19. Insert the applicator tool into the HVAC filter opening. 20. Spray the full contents of the water onto the evaporator continuously while moving the applicator tool up and down and back and forth so that the evaporator is evenly covered with water. 21. Install the HVAC filter cover (do not install the HVAC filter at this time). 22. Start the engine. 23. Raise all the windows to a slightly open position (about 1/2 inch opening). 24. Set the blower to HIGH. 25. Set the A/C switch to NC OFF. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7390 26. Set mode switch to PANEL OUTLETS. 27. Set temperature switch to FULL HEAT. 28. Set recirculation switch to RECIRCULATE. 29. With the engine running, allow the blower to operate for 20 minutes. 30. Turn the ignition switch to the OFF position. 31. Raise the vehicle on a suitable hoist. 32. Clamp off the drain tube using a suitable clamp. 33. Lower the vehicle. CAUTION: Technician must use eye protection, rubber gloves, protective clothing, and avoid breathing vapors. 34. Open all windows in the vehicle. 35. Remove the HVAC filter cover. 36. Shake a 8 ounce bottle of Cooling Coil Coating (p/n 04728942AB), and screw the bottle onto the applicator tool. 37. Insert the applicator tool into the blower resistor opening. Spray the full contents of the bottle onto the evaporator while moving the applicator tool up and down and back and forth so that the evaporator is evenly coated. 38. Allow the vehicle to sit for 30 minutes. 39. Install the HVAC filter. Replace with a new filter, p/n 05103600AA, if necessary. 40. Install the HVAC filter cover. 41. Raise the vehicle on a suitable hoist. CAUTION: The excess cooling coil coating will drain when the cap/clamp/plug is removed in the next step. 42. Remove the drain tube clamp. 43. Lower the vehicle. 44. Start the engine. 45. Raise all the windows to a slightly open position (about 1/2 inch opening). 46. Set the blower to HIGH. 47. Set the A/C switch to A/C OFF. 48. Set mode switch to PANEL OUTLETS. 49. Set temperature switch to FULL HEAT. 50. Set recirculation switch to RECIRCULATE. 51. With the engine running, allow the blower motor to operate for 20 minutes. 52. Turn the ignition switch to the OFF position. 53. Fill an 8 ounce plastic bottle with warm water and screw onto applicator tool. Clean tool by spraying warm water under pressure into the shop sink. Wipe the tool and store for next use. 54. Raise the vehicle on a suitable hoist. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-006-06 > Aug > 06 > A/C - Musty Odors When Hot/Humid > Page 7391 CAUTION: In the following step be careful not to damage the A/C cooling coil. 55. Using a suitable object (a wire coat hanger for example), probe the drain tube 3.8 - 5.1 cm (1.5 - 2 in.) to ensure that the dried coil coating is not restricting the flow from the drain tube. 56. Lower the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Front Evaporator Core: Description and Operation Front A/C Evaporator The A/C evaporator for the front heating-A/C system is located within the front HVAC housing, behind the instrument panel. The front A/C evaporator and insulator are positioned in the front HVAC housing so that all air entering the housing must pass over the evaporator fins before it is distributed through the front heating-A/C system ducts and outlets. However, air passing over the evaporator fins will only be conditioned when the A/C compressor is engaged and circulating refrigerant through the front A/C evaporator. The front A/C evaporator tubes are connected and sealed to the A/C expansion valve by use of rubber O-rings and a tapping block. The front A/C evaporator can only be serviced by removing and disassembling the front HVAC housing. Refrigerant enters the front A/C evaporator from the front A/C expansion valve as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the front A/C evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the front A/C evaporator. The front A/C evaporator cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Front > Page 7394 Evaporator Core: Description and Operation Rear Rear A/C Evaporator The A/C evaporator for the rear heating-A/C system is located within the rear HVAC housing, behind the right quarter trim panel. The rear A/C evaporator is positioned in the rear HVAC housing so that all air entering the housing must pass over the evaporator fins before it is distributed through the rear heating-A/C system ducts and outlets. However, air passing over the evaporator fins will only be conditioned when the A/C compressor is engaged and circulating refrigerant through the rear A/C evaporator. The rear A/C evaporator tubes are connected and sealed to the rear A/C expansion valve by use of rubber O-rings and a tapping block. The rear A/C evaporator can only be serviced by removing and disassembling the rear HVAC housing. Refrigerant enters the rear A/C evaporator from the rear A/C expansion valve as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the rear A/C evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the rear A/C evaporator. The rear A/C evaporator cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator Evaporator Core: Service and Repair Front A/C Evaporator REMOVAL See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel Service and Repair A/C Evaporator 1. Remove the front HVAC housing. 2. Disassemble the front HVAC housing as necessary to access the front A/C evaporator. 3. Open the rubber flange seal and carefully lift the front A/C evaporator and insulator out of the lower half of the front HVAC housing. NOTE: If the insulator is deformed or damaged, it must be replaced. 4. If required, remove the insulator from the front A/C evaporator. INSTALLATION NOTE: If the front A/C evaporator is being replaced, add 50 milliliters (1.7 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 1. If removed, install the insulator over the front A/C evaporator. NOTE: Make sure that the evaporator drain within the front HVAC housing is clean and unrestricted and that the insulator and the rubber flange seal are properly positioned. 2. Install the front A/C evaporator into the lower half of the front HVAC housing and close the rubber flange seal. 3. Assemble the front HVAC housing. 4. Install the front HVAC housing. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator > Page 7397 Evaporator Core: Service and Repair Rear Evaporator REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Remove the rear HVAC housing from the vehicle. 2. Remove the rear evaporator line extension from the rear A/C expansion valve. 3. Remove the rear A/C expansion valve from the rear A/C evaporator. 4. Remove the rubber grommet that seals the evaporator inlet and outlet tubes to the rear HVAC housing near the rear A/C expansion valve. Rear A/C Evaporator 5. Remove the three screws that secure the upper half of the rear HVAC housing to the lower half. 6. Remove the three metal spring clips that secure the upper half of the rear HVAC housing to the lower half. 7. Carefully separate and remove the upper half of the rear HVAC housing from the lower half. 8. Remove the rear A/C evaporator from the lower half of the rear HVAC housing. INSTALLATION NOTE: If the rear A/C evaporator is being replaced, add 50 milliliters (1.7 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 1. Carefully lower the rear A/C evaporator and its foam wrap into the lower half of the rear HVAC housing. 2. Position the upper half of the rear HVAC housing onto the lower half. 3. Install the three metal spring clips that secure the upper half of the rear HVAC housing to the lower half. 4. Install the three screws that secure the upper half of the rear HVAC housing to the lower half. Tighten the screws to 2 N.m (17 in. lbs.). 5. Install the rubber grommet that seals the evaporator inlet and outlet tubes to the rear HVAC housing near the rear A/C expansion valve. 6. Install the rear A/C expansion valve onto the rear A/C evaporator. 7. Install the rear evaporator extension line onto the rear A/C expansion valve. 8. Install the rear HVAC housing. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator > Page 7398 Evaporator Core: Service and Repair Rear Evaporator Line Extension REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Remove the rear HVAC housing. Evaporator Line Extension Plate 2. Remove the screw that secures the flange to the rear HVAC housing and remove the flange. Rear A/C Evaporator Line Extension 3. Carefully remove the foam insulating from the bottom of the rear A/C expansion valve to gain access to the evaporator line extension sealing plate. 4. Remove the two screws that secure the expansion valve bracket to the lower rear HVAC housing. 5. Remove the nut that secures the expansion valve bracket to the expansion valve stud and remove the bracket. 6. Remove the nut that secures the evaporator line extension seal plate to the expansion valve stud and remove the seal plate. 7. Remove the evaporator line extension from the rear A/C expansion valve and the lower rear HVAC housing. 8. Remove the seals from the evaporator line extension fittings and discard. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator > Page 7399 9. Install plugs in, or tape over the opened evaporator line extension fittings and both expansion valve ports. INSTALLATION 1. Remove the tape or plugs from the evaporator line extension fittings and both expansion valve ports. 2. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the evaporator line extension fittings. 3. Position the evaporator line extension to the rear A/C expansion valve and the lower rear HVAC housing. 4. Position the evaporator line extension seal plate over the expansion valve stud. 5. Install the nut that secures the evaporator line extension seal plate to the expansion valve stud. Tighten the nut to 23 N.m (17 ft. lbs.). 6. Position the expansion valve bracket over the expansion valve stud. 7. Install the two screws that secure the expansion valve bracket to the lower rear HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.). 8. Install the nut that secures the expansion valve bracket to the expansion valve stud. Tighten the nut to 23 N.m (17 ft. lbs.). 9. Install the foam insulating over the rear A/C expansion valve. 10. Position the flange over the rear evaporator line extension and into the lower rear HVAC housing. 11. Install the screw that secures the flange to the rear lower HVAC housing. Tighten the screw to 2 N.m (17 in. lbs.). 12. Install the rear HVAC housing. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 24-001-06A > Nov > 06 > A/C - Water leaks Under Passenger Side Carpet Evaporator Drain Tube: Customer Interest A/C - Water leaks Under Passenger Side Carpet NUMBER: 24-001-06 REV A GROUP: Heating & A/C DATE: November 10, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-001-06, DATED FEBRUARY 23, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION IS HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL VEHICLE AND MODEL YEARS. SUBJECT: HVAC Drain Water (AC Condensate) Leaks Under Passenger Side Carpet OVERVIEW: This bulletin involves installing a HVAC drain tube 0-ring. MODELS: **2004 - 2006 (CS) Pacifica** 2001 - 2006 (RS) Town & Country/Caravan/Voyager 2001 - 2006 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to vehicles built on or before December 16, 2005 (MDH 1216XX). SYMPTOM/CONDITION: The customer may describe a wet front passenger floor or floor carpet. This condition may be due to water (A/C condensate) from the HVAC assembly drain tube. DIAGNOSIS: Verify the passenger side front floor or carpet is wet. Check the source of the water leak. As A/C condensate leaves the HVAC drain tube, it may run back along the outside of the drain tube, past the seal, and under the passenger side front floor carpet. If the HVAC assembly drain tube is the cause of the water leak, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Disconnect the battery. 2. Disconnect the inlet air temperature sensor. 3. Loosen the clamp and remove the inlet hose from the throttle body (leave the other end attached to the air cleaner housing cover). 4. Remove the air cleaner housing cover. 5. Inspect the HVAC drain tube. Clean out any debris or other restrictions in the drain. 6. Install the HVAC drain 0-ring onto the HVAC drain tube, making sure the 0-ring is 6 mm (0.25 in.) onto the keyway on the top of the HVAC drain and beyond the slot in the bottom of the HVAC drain. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 24-001-06A > Nov > 06 > A/C - Water leaks Under Passenger Side Carpet > Page 7408 7. Install the air cleaner housing cover. 8. Attach the inlet hose to the throttle body and tighten clamp. 9. Reconnect the inlet air temperature sensor. 10. Reconnect the battery. 11. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 24-001-06 > Feb > 06 > A/C - Water Leaks Under Passenger Side Carpet Evaporator Drain Tube: Customer Interest A/C - Water Leaks Under Passenger Side Carpet NUMBER: 24-001-06 GROUP: Heating & A/C DATE: February 23, 2006 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MARCH 1, 2006. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-008-02 REV. A, DATED NOVEMBER 22,2002, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: HVAC Drain Water (AC Condensate) Leaks Under Passenger Side Carpet OVERVIEW: This bulletin involves installing a HVAC drain tube 0-ring. MODELS: 2001 - 2006 (RS) Town & Country/Caravan/Voyager 2001 - 2006 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to vehicles built on or before December 16, 2005 (MDH 1216XX). SYMPTOM/CONDITION: The customer may describe a wet front passenger floor or floor carpet. This condition may be due to water (A/C condensate) from the HVAC assembly drain tube. DIAGNOSIS: Verify the passenger side front floor or carpet is wet. Check the source of the water leak. As A/C condensate leaves the HVAC drain tube, it may run back along the outside of the drain tube, past the seal, and under the passenger side front floor carpet. If the HVAC assembly drain tube is the cause of the water leak, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Disconnect the battery. 2. Disconnect the inlet air temperature sensor. 3. Loosen the clamp and remove the inlet hose from the throttle body (leave the other end attached to the air cleaner housing cover). 4. Remove the air cleaner housing cover. 5. Inspect the HVAC drain tube. Clean out any debris or other restrictions in the drain. 6. Install the HVAC drain 0-ring onto the HVAC drain tube, making sure the 0-ring is 6 mm (0.25 in.) onto the keyway on the top of the HVAC drain and beyond the slot in the bottom of the HVAC drain. 7. Install the air cleaner housing cover. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 24-001-06 > Feb > 06 > A/C - Water Leaks Under Passenger Side Carpet > Page 7413 8. Attach the inlet hose to the throttle body and tighten clamp. 9. Reconnect the inlet air temperature sensor. 10. Reconnect the battery. 11. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 24-001-06A > Nov > 06 > A/C - Water leaks Under Passenger Side Carpet Evaporator Drain Tube: All Technical Service Bulletins A/C - Water leaks Under Passenger Side Carpet NUMBER: 24-001-06 REV A GROUP: Heating & A/C DATE: November 10, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-001-06, DATED FEBRUARY 23, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION IS HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL VEHICLE AND MODEL YEARS. SUBJECT: HVAC Drain Water (AC Condensate) Leaks Under Passenger Side Carpet OVERVIEW: This bulletin involves installing a HVAC drain tube 0-ring. MODELS: **2004 - 2006 (CS) Pacifica** 2001 - 2006 (RS) Town & Country/Caravan/Voyager 2001 - 2006 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to vehicles built on or before December 16, 2005 (MDH 1216XX). SYMPTOM/CONDITION: The customer may describe a wet front passenger floor or floor carpet. This condition may be due to water (A/C condensate) from the HVAC assembly drain tube. DIAGNOSIS: Verify the passenger side front floor or carpet is wet. Check the source of the water leak. As A/C condensate leaves the HVAC drain tube, it may run back along the outside of the drain tube, past the seal, and under the passenger side front floor carpet. If the HVAC assembly drain tube is the cause of the water leak, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Disconnect the battery. 2. Disconnect the inlet air temperature sensor. 3. Loosen the clamp and remove the inlet hose from the throttle body (leave the other end attached to the air cleaner housing cover). 4. Remove the air cleaner housing cover. 5. Inspect the HVAC drain tube. Clean out any debris or other restrictions in the drain. 6. Install the HVAC drain 0-ring onto the HVAC drain tube, making sure the 0-ring is 6 mm (0.25 in.) onto the keyway on the top of the HVAC drain and beyond the slot in the bottom of the HVAC drain. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 24-001-06A > Nov > 06 > A/C - Water leaks Under Passenger Side Carpet > Page 7419 7. Install the air cleaner housing cover. 8. Attach the inlet hose to the throttle body and tighten clamp. 9. Reconnect the inlet air temperature sensor. 10. Reconnect the battery. 11. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 24-001-06 > Feb > 06 > A/C - Water Leaks Under Passenger Side Carpet Evaporator Drain Tube: All Technical Service Bulletins A/C - Water Leaks Under Passenger Side Carpet NUMBER: 24-001-06 GROUP: Heating & A/C DATE: February 23, 2006 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL MARCH 1, 2006. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-008-02 REV. A, DATED NOVEMBER 22,2002, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: HVAC Drain Water (AC Condensate) Leaks Under Passenger Side Carpet OVERVIEW: This bulletin involves installing a HVAC drain tube 0-ring. MODELS: 2001 - 2006 (RS) Town & Country/Caravan/Voyager 2001 - 2006 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to vehicles built on or before December 16, 2005 (MDH 1216XX). SYMPTOM/CONDITION: The customer may describe a wet front passenger floor or floor carpet. This condition may be due to water (A/C condensate) from the HVAC assembly drain tube. DIAGNOSIS: Verify the passenger side front floor or carpet is wet. Check the source of the water leak. As A/C condensate leaves the HVAC drain tube, it may run back along the outside of the drain tube, past the seal, and under the passenger side front floor carpet. If the HVAC assembly drain tube is the cause of the water leak, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Disconnect the battery. 2. Disconnect the inlet air temperature sensor. 3. Loosen the clamp and remove the inlet hose from the throttle body (leave the other end attached to the air cleaner housing cover). 4. Remove the air cleaner housing cover. 5. Inspect the HVAC drain tube. Clean out any debris or other restrictions in the drain. 6. Install the HVAC drain 0-ring onto the HVAC drain tube, making sure the 0-ring is 6 mm (0.25 in.) onto the keyway on the top of the HVAC drain and beyond the slot in the bottom of the HVAC drain. 7. Install the air cleaner housing cover. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 24-001-06 > Feb > 06 > A/C - Water Leaks Under Passenger Side Carpet > Page 7424 8. Attach the inlet hose to the throttle body and tighten clamp. 9. Reconnect the inlet air temperature sensor. 10. Reconnect the battery. 11. Set the clock to the correct time. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7428 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7429 Evaporator Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7430 Evaporator Temperature Sensor / Switch: Description and Operation Evaporator Temperature Sensor - Typical The evaporator temperature sensor used for the manual and automatic temperature control systems on RS models is installed on the top of the HVAC housing behind the instrument panel and measures the air temperature downstream of the evaporator. The sensor is an electrical thermistor in a plastic housing that is inserted into the HVAC housing. Two terminals within the molded plastic connector receptacle on the sensor connect it to the vehicle electrical system through a take out and connector of the HVAC wire harness. Evaporator Temperature Sensor - RG Models The evaporator temperature sensor used for the manual and automatic temperature control systems on RG models is installed on the top of the expansion valve in the right rear corner of the engine compartment and measures the temperature of the evaporator coils. The sensor has a small probe that is Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7431 inserted in a small well in the body of the expansion valve that is filled with a special silicone-based thermal grease. A small molded plastic push-in retainer secures the sensor to a threaded hole in the top surface of the expansion valve. Two terminals within a molded plastic connector receptacle on the sensor connect it to the vehicle electrical system through a take out and connector of the HVAC wire harness. The evaporator temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The evaporator temperature sensor monitors the temperature of the conditioned air once it passes through the A/C evaporator. The evaporator temperature sensor will change its internal resistance in response to the air temperatures it monitors and is connected to the A/C-heater control through sensor ground and signal circuits. As the conditioned air temperature increases, the resistance of the evaporator temperature sensor decreases and the voltage monitored by the A/C-heater control decreases. The external location of the evaporator temperature sensor allows the sensor to be removed or installed without disturbing the refrigerant in the A/C system. The A/C-heater control uses this monitored voltage reading as an indication of the evaporator temperature. The A/C-heater control is programmed to respond to this input by sending electronic messages to the powertrain control module (PCM) over the controller area network (CAN) data bus. The PCM then cycles the A/C compressor clutch as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The evaporator temperature sensor is diagnosed using the DRBIII(R) scan tool. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > RG Models Evaporator Temperature Sensor / Switch: Service and Repair RG Models REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the air cleaner housing from the right side of the engine compartment. 3. Remove the windshield wiper assembly from the vehicle. 4. If equipped with rear A/C, disconnect the liquid and suction lines from the A/C expansion valve. Evaporator Temperature Sensor (RG Models) - Rear A/C Shown 5. Remove the retainer that secures the evaporator temperature sensor to the A/C expansion valve. NOTE: To disconnect the wire harness connector from the evaporator temperature sensor, first push the red retaining ring toward the connector to release the lock, then disconnect the connector from the sensor. 6. Remove the evaporator temperature sensor from the A/C expansion valve and disconnect the wire harness connector. INSTALLATION NOTE: Any grease removed with the evaporator temperature sensor must be replaced. Failure to do so could result in poor A/C performance. 1. Position the evaporator temperature sensor into the right rear corner of the engine compartment. NOTE: To connect the wire harness connector to the evaporator temperature sensor, first connect the connector to the sensor, then pull the red retaining ring toward the sensor. 2. Connect the wire harness connector to the evaporator temperature sensor. 3. Install the evaporator temperature sensor onto the top of the expansion valve with the sensor probe inserted into the well in the expansion valve. 4. Install the temperature sensor retainer. 5. If equipped with rear A/C, connect the liquid and suction lines to the A/C expansion valve and recharge the A/C system. 6. Install the window wiper module. 7. Install the air cleaner housing into the right side of the engine compartment. 8. Reconnect the negative battery cable. 9. Run the HVAC Cool Down test to verify system is operating properly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > RG Models > Page 7434 Evaporator Temperature Sensor / Switch: Service and Repair RS Models REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel from the vehicle. Evaporator Temperature Sensor - RS Models 3. Disconnect the wire harness connector from the evaporator temperature sensor located on the top of the HVAC housing. 4. Remove the evaporator temperature sensor from the HVAC housing. INSTALLATION 1. Install the evaporator temperature sensor into the top of the HVAC housing. 2. Connect the wire harness connector to the evaporator temperature sensor. 3. Install the instrument panel. 4. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > Front Expansion Valve: Description and Operation Front The front A/C expansion valve controls the amount of refrigerant entering the front A/C evaporator. The front A/C expansion valve is of a thermostatic expansion valve (TXV) design and consists of an aluminum H-valve type body with an integral thermal sensor. The front A/C expansion valve is located in the engine compartment at the dash panel, between the A/C refrigerant lines and the A/C evaporator. On RG models, the evaporator temperature sensor is installed on the top of the front A/C expansion valve. The A/C expansion valve controls the high-pressure, low temperature liquid refrigerant from the liquid line and converts it into a low-pressure, low-temperature mixture of liquid and gas before it enters the A/C evaporator. A mechanical sensor in the A/C expansion valve monitors the temperature and pressure of the refrigerant leaving the A/C evaporator through the suction line, and adjusts the orifice size at the liquid line port to let the proper amount of refrigerant into the A/C evaporator to meet the vehicle A/C cooling requirements. Controlling the refrigerant flow through the A/C evaporator ensures that none of the refrigerant leaving the A/C evaporator is still in a liquid state, which could damage the A/C compressor. The A/C expansion valve is a factory calibrated unit and cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > Front > Page 7440 Expansion Valve: Description and Operation Rear The rear "H" valve-type thermal expansion valve (TXV) is located at the rear of the rear HVAC housing between the evaporator line extension and the evaporator coil. High-pressure, low temperature liquid refrigerant from the liquid line passes through the expansion valve orifice, converting it into a low pressure, low-temperature mixture of liquid and gas before it enters the evaporator coil. The rear A/C expansion valve controls the high-pressure, low temperature liquid refrigerant from the rear liquid line and converts it into a low-pressure, low-temperature mixture of liquid and gas before it enters the rear A/C evaporator. A mechanical sensor in the rear A/C expansion valve monitors the temperature and pressure of the refrigerant leaving the rear A/C evaporator through the rear suction line, and adjusts the orifice size at the rear liquid line port to let the proper amount of refrigerant into the rear A/C evaporator to meet the vehicle A/C cooling requirements. Controlling the refrigerant flow through the rear A/C evaporator ensures that none of the refrigerant leaving the rear A/C evaporator is still in a liquid state, which could damage the A/C compressor. For diagnosis and testing of the rear A/C expansion valve, refer to testing. The rear A/C expansion valve is factory calibrated and cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > Page 7441 Expansion Valve: Testing and Inspection WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: - The A/C expansion valve should only be tested following testing of the A/C compressor. - Liquid CO2 is required to test the A/C expansion valve. This material is available from most welding supply facilities. Liquid CO2 is also available from companies which service and sell fire extinguishers. When testing the A/C expansion valve, the work area and the vehicle temperature must be 21° to 27° C (70° to 85° F). To test the expansion valve: 1. Connect a charging station or manifold gauge set to the refrigerant system service ports. Verify the refrigerant charge level. 2. Close all doors, windows and vents to the passenger compartment. 3. Set the A/C-heater controls so that the A/C compressor is operating, the temperature control is in the highest temperature position, the mode-air doors is directing air output to the floor and the blower motor operating is operating at the highest speed. 4. Start the engine and allow it to idle. After the engine has reached normal operating temperature, allow the passenger compartment to heat up. This will create the need for maximum refrigerant flow into the A/C evaporator. 5. If the refrigerant charge is sufficient, the discharge (high pressure) gauge should read 965 kPa to 1655 kPa (140 psi to 240 psi). The suction (low pressure) gauge should read 138 kPa to 207 kPa (20 psi to 30 psi). If OK, go to Step 6. If not OK, replace the faulty A/C expansion valve. WARNING: PROTECT THE SKIN AND EYES FROM EXPOSURE TO LIQUID CO2OR PERSONAL INJURY CAN RESULT. 6. If the suction (low pressure) gauge reads within the specified range, freeze the A/C expansion valve for 30 seconds using liquid CO2or another suitable super-cold material.Do not spray R-134a or R-12 refrigerant on the A/C expansion valve for this test. The suction (low pressure) gauge reading should drop by 69 kPa (10 psi). If OK, go to Step 7 If not OK, replace the faulty A/C expansion valve. 7. Allow the expansion valve control head to thaw. The suction (low pressure) gauge reading should stabilize at 138 kPa to 207 kPa (20 psi to 30 psi). If not OK, replace the faulty A/C expansion valve. 8. When expansion valve testing is complete, test the overall A/C system performance. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Front Expansion Valve: Service and Repair Front REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Remove the air cleaner housing and the air inlet tube. 4. Remove the drain tube from the right end of the wiper module. A/C Expansion Valve - LHD Shown, RHD Typical 5. Disconnect the wire harness connector from the A/C pressure transducer. 6. Remove the screw that secures the liquid line to the receiver/drier outlet port. 7. Disconnect the liquid line from the receiver/ drier outlet port and remove and discard the seal. 8. Install plugs in, or tape over the opened liquid line fitting and the receiver/drier outlet port. 9. Remove the nut that secures the suction line and liquid line fittings to the stud on the A/C expansion valve. 10. Disconnect the A/C suction and liquid line fittings from the A/C expansion valve and remove and discard the seals. 11. Install plugs in, or tape over the opened suction line and liquid line fittings and both expansion valve ports. 12. On RG models, disconnect the HVAC wire harness connector from the evaporator temperature sensor. 13. Remove the two screws that secure the A/C expansion valve to the evaporator tube tapping plate and remove the expansion valve. 14. Remove the seals from the evaporator inlet and outlet tube fittings and discard. 15. Install plugs in, or tape over the opened evaporator inlet and outlet tube fittings and both expansion valve ports. 16. On RG models, remove the retaining screw and evaporator temperature sensor from the A/C expansion valve, if required. INSTALLATION NOTE: Any grease removed with the evaporator temperature sensor must be replaced. Failure to do so could result in poor A/C performance. 1. On RG models, install the evaporator temperature sensor and retainer onto the A/C expansion valve, if removed. 2. Remove the tape or plugs from the evaporator inlet and outlet tube fittings and both ports on the back of the A/C expansion valve. 3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the evaporator inlet and outlet tube fittings. 4. Position the A/C expansion valve onto the evaporator inlet and outlet tube fittings. 5. Install the two screws that secure the A/C expansion valve to the evaporator tube tapping plate plate. Tighten the screws to 11 N.m (97 in. lbs.). 6. On RG models, connect the HVAC wire harness connector to the evaporator temperature sensor. 7. Remove the tape or plugs from the front liquid line rear and suction line fittings for the expansion valve and both ports on the front of the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Front > Page 7444 expansion valve. 8. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the front liquid line rear and suction line fittings for the expansion valve. 9. Connect the A/C liquid and suction lines to the expansion valve. 10. Install the nut that secures the A/C liquid and suction lines to the expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.). 11. Remove the tape or plugs from the liquid line rear fitting and the receiver/drier outlet port. 12. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting. 13. Connect the liquid line fitting to the receiver/ drier outlet port. 14. Install the screw that secures the liquid line fitting to the receiver/drier. Tighten the screw to 11 N.m (97 in. lbs.). 15. Connect the wire harness connector to the A/C pressure transducer. 16. Install the drain tube to the wiper module. 17. Install the air cleaner housing and air inlet tube. 18. Reconnect the negative battery cable. 19. Evacuate the refrigerant system. 20. Charge the refrigerant system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Front > Page 7445 Expansion Valve: Service and Repair Rear REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Remove the rear HVAC housing. Rear A/C Evaporator Line Extension 2. Carefully remove the foam insulating from around the rear A/C expansion valve. 3. Remove the rear evaporator line extension from the rear A/C expansion valve. 4. Remove the two screws that secure the rear A/C expansion valve to the rear evaporator tube sealing plate. 5. Remove the rear A/C expansion valve from the rear evaporator tubes and remove and discard the seals. 6. Install plugs in, or tape over the opened evaporator tube fittings, evaporator ports and all expansion valve ports. INSTALLATION 1. Remove the tape or plugs from the rear A/C evaporator tube fittings, rear A/C evaporator ports and all rear expansion valve ports. 2. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the rear evaporator tube fittings. 3. Position the rear A/C expansion valve onto the rear evaporator tubes. 4. Install the two screws that secure the rear A/C expansion valve to the rear evaporator tube sealing plate. Tighten the screws to 11 N.m (97 in. lbs.). 5. Install the rear evaporator line extension onto the rear A/C expansion valve. 6. Install the foam insulating over the rear A/C expansion valve. 7. Install the rear HVAC housing. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Front Heater Core: Description and Operation Front Heater Core The front heater core is mounted into the HVAC air distribution housing, located behind the instrument panel. The heater core is a heat exchanger made of rows of tubes and fins. The heater core tubes are attached to the heater core by a sealing plate and bolt. The heater core can be serviced without removing the air distribution housing from the vehicle. Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed through the heater core picks up the heat from the heater core fins. The blend-air door(s) allows control of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Front > Page 7450 Heater Core: Description and Operation Rear Rear Heater Core The rear heater core is located near the front of the rear HVAC housing, behind the right rear wheel house. It is a heat exchanger made of rows of tubes and fins. One end of the heater core is fitted with a molded plastic tank that includes the mounting provisions for the heater core and connections for the heater core inlet and outlet tubes. The rear heater core can be serviced without removing the rear HVAC housing from the vehicle. Engine coolant is circulated through underbody heater hoses to the rear heater core at all times. As the coolant flows through the rear heater core, heat removed from the engine is transferred to the heater core fins and tubes. Air directed through the heater core picks up the heat from the heater core fins. The rear blend-air door allows control of the rear heater output air temperature by controlling how much of the air flowing through the rear HVAC housing is directed through the rear heater core. The rear heater core cannot be repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Page 7451 Heater Core: Testing and Inspection Successful completion of the rear heater performance check will confirm that the rear heater core is properly filled with engine coolant. If the check is not successful, either there is still air trapped in the rear heater core or the rear heater plumbing is restricted. This check should be performed with the vehicle in a shop where the ambient temperature is about 21° C (70° F). 1. Start the engine and allow it to idle until it warms up to normal operating temperature. 2. Adjust the A/C-heater controls so that the front heater is turned Off and the rear heater is set for full Heat with the rear blower motor at its highest speed setting. 3. Use an accurate test thermometer to measure the temperature of the air being discharged from the rear heater outlet located at the base of the right C-pillar. 4. Proper discharge air temperature readings should be from 57° to 63° C (135° to 145° F). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core: Service and Repair Front Removal - FRONT HEATER CORE WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death. WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death. 1. Remove the silencer boot fasteners located around the base of the lower steering shaft from the dash panel so that it may be pushed aside. 2. Remove the brake lamp switch from its mounting bracket. 3. Disconnect the power brake booster input rod (push rod) from the pin on the brake pedal arm. 4. If equipped with power adjustable pedals, remove the adjustable pedal assembly. NOTE: Take the proper precautions to protect the carpeting below the heater core from spilled engine coolant and have absorbent toweling readily available to clean up any spills. 5. Remove the heater core tubes. 6. Remove the two screws that secure the heater core mounting plate to the HVAC air distribution housing. 7. If NOT equipped with power adjustable pedals, pull the accelerator pedal upward (Accelerator Pedal) and push the brake pedal downward (Brake Pedal) for clearance to remove the heater core from the air distribution housing. 8. Remove the heater core by carefully pulling it straight out of the side of the air distribution housing. Installation - FRONT HEATER CORE 1. If NOT equipped with power adjustable pedals, pull the accelerator pedal upward and push the brake pedal downward for clearance to install the heater core into the HVAC air distribution housing. 2. Install the heater core by carefully pushing it straight into the side of the air distribution housing. 3. Install the two screws that secure the heater core to the air distribution housing. Tighten the screws to 2 Nm (17 in. lbs.). 4. Install the heater core tubes. 5. If equipped with power adjustable pedals, install the adjustable pedal assembly 6. Connect the power brake booster input rod (push rod) to the pin on the brake pedal arm. 7. Install the brake lamp switch into its mounting bracket. 8. Install the silencer boot around the base of the lower steering shaft on the dash panel. 9. Reconnect the negative battery cable. 10. If the heater core is being replaced, flush the cooling system. 11. Refill the engine cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front > Page 7454 Heater Core: Service and Repair Front Heater Core Tubes REMOVAL WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. - REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Drain the engine cooling system. 2. Disconnect and isolate the negative battery cable. 3. Disconnect the heater hoses from the heater core tubes. 4. Remove the silencer from beneath the driver side end of the instrument panel. NOTE: Take the proper precautions to protect the carpeting below the heater core from spilled engine coolant and have absorbent toweling readily available to clean up any spills. Heater Core Tubes 5. Remove the screw that secures the heater core tube sealing plate to the heater core. 6. Push both heater core tubes simultaneously toward the dash panel and disengage the tubes from the heater core. 7. Install plugs in, or tape over the opened heater core tube fittings and both heater core ports. 8. Pull both heater core tubes simultaneously away from the distribution housing and rearward to disengage tubes from the dash panel seal and remove the tubes. INSTALLATION 1. Remove the plugs or tape from both heater core tube fittings and both heater core ports. 2. Position the heater core tubes and sealing plate to the dash panel, below the instrument panel. 3. Install both heater core tubes simultaneously through the dash panel seal. 4. Position both heater core tubes and the sealing plate simultaneously onto the heater core. NOTE: The heater core tubes each have a slot that must be indexed to a location tab within each of the heater core ports. Adjust the position of the tubes as required so that the sealing plate fits flush against the heater core supply and return ports, which indicates that the tubes are properly indexed. 5. Index both heater core tubes to the heater core ports. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front > Page 7455 6. Install the bolt that secures the heater core tube sealing plate to the heater core. Tighten the bolt to 3 N.m (27 in. lbs.). 7. Install the silencer under the driver side end of the instrument panel. 8. Connect the heater hoses to the heater hose tubes. 9. Reconnect the negative battery cable. 10. Refill the engine cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front > Page 7456 Heater Core: Service and Repair Rear Heater Core Filling WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. The rear heater core is positioned in the rear HVAC housing at a higher level than the radiator fill opening. Therefore, when the cooling system is drained and refilled, gravity will not totally refill the rear heater core. This may result in two problems: 1. Insufficient coolant level in the engine cooling system, which may result in engine overheating. 2. Air entrapped within the rear heater core, which may result in insufficient rear heater performance. There are two methods that may be employed to prevent these problems: 1. Pre-filling of the rear heater core. 2. Thermal cycling of the engine cooling system. Following are descriptions of both prevention methods, as well as a method to verify rear heater performance. PRE-FILLING NOTE: Take the proper precautions to protect the carpeting below the heater core from spilled engine coolant and have absorbent toweling readily available to clean up any spills. If the rear heater core or the rear HVAC housing have been removed from the vehicle for service, the rear heater core may be pre-filled with the proper engine coolant mixture prior to reconnecting the heater hoses to the heater core hose fittings. 1. The heater core should be installed in the rear HVAC housing, and the rear HVAC housing should be installed in the vehicle. Pre-Filling Heater Core - Typical 2. Insert the small end of an appropriate funnel into the upper hose fitting of the heater core. 3. Carefully pour the proper pre-mixed engine coolant solution into the rear heater core through a funnel until coolant begins to appear at the lower hose fitting of the rear heater core. 4. Connect the heater hoses to the rear heater core tubes. 5. Refill the engine cooling system. THERMAL CYCLING If the rear heater core was emptied and was not pre-filled, it will be necessary to thermal cycle the vehicle at least two times to ensure that the rear heater core is properly filled. 1. Refill the engine cooling system. 2. Start the engine and allow it to operate until the thermostat opens. 3. Turn the engine off and allow it to cool. 4. With the engine cold and not running, check and top off the engine coolant level as necessary. 5. Start the engine and allow it to operate until the thermostat opens again. 6. Turn the engine off and allow it to cool down again. 7. With the engine cold and not running, check and top off the engine coolant level as necessary. 8. Check the performance of the rear heater. Refer to REAR HEATER PERFORMANCE CHECK. See: Testing and Inspection Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front > Page 7457 Heater Core: Service and Repair Removal and Installation REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Drain the engine cooling system. 2. Remove the trim panels from the right inner quarter panel and the right D-pillar. 3. Remove the rear heater distribution duct. 4. Remove the screw that secures the back of the rear HVAC housing to the right D-pillar. 5. Remove the screw that secures the front of the rear HVAC housing to the right inner quarter panel. NOTE: Take the proper precautions to protect the carpeting below the heater core from spilled engine coolant and have absorbent toweling readily available to clean up any spills. 6. Disconnect the heater hoses from the rear heater core. Rear Heater Core 7. Install plugs in, or tape over the opened heater core fittings and both heater hoses. 8. Release the four retaining tabs that secure the rear heater core to the rear HVAC housing and remove the heater core. INSTALLATION NOTE: If the rear heater core or the rear HVAC housing have been removed from the vehicle for service, the rear heater core should be pre-filled with the proper engine coolant mixture prior to reconnecting the heater hoses to the heater core hose fittings. 1. Carefully position the rear heater core into the rear HVAC housing. 2. Using hand pressure, press firmly and evenly on the molded plastic tank of the rear heater core until the four retaining tabs that secure the rear heater core in the rear HVAC housing fully engage. 3. Remove the plugs or tape from the rear heater core fittings and both rear heater hoses. 4. Pre-fill the rear heater core. 5. Connect the rear heater hoses to the rear heater core. 6. Install the screw that secures the front of the rear HVAC housing to the right inner quarter panel. Tighten the screw to 11 N.m (97 in. lbs.). 7. Install the screw that secures the back of the rear HVAC housing to the right D-pillar. Tighten the screw to 11 N.m (97 in. lbs.). 8. Install the rear distribution duct. 9. Install the trim panels onto the right inner quarter panel and the right D-pillar. 10. If the heater core is being replaced, flush the cooling system. 11. Refill the engine cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Recalls for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement Technical Service Bulletin # F06 Date: 060401 Campaign - Underbody Heater Hose Replacement April 2006 Dealer Service Instructions for: Customer Satisfaction Notification F06 Underbody Heater Hoses Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 05-028 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2005 (RS) Dodge Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles equipped with rear Heater/Air Conditioning (sales code HBB) and Stow-n-Go seats (sales code CYC) or Stow-N-Go floor pan (sales code CYY or CYV). IMPORTANT: The above vehicles located in the "salt belt" are involved in Customer Satisfaction Notification F01 (Rear A/C Heater tube Corrosion) and therefore have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The underbody heater hoses on about 141,000 of the above vehicles may leak coolant at the heater tube crimps. This may result in the engine overheating. Engine damage can occur if an overheated engine continues to be driven. Repair The underbody heater hoses for the rear heater must be replaced. Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Recalls for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 7466 Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the hood. 2. Lower the spare tire using the crank handle inside the vehicle (approximately 10 turns). 3. Using pinch-off pliers, clamp off the heater hoses in the engine compartment that connect the rear heater tubes to the engine cooling system. 4. Lift the vehicle on an appropriate hoist. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Recalls for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 7467 5. Using a cut off wheel, grind a slot into the heater tube aluminum crimp band on the two rear heater hoses (Figure 1). CAUTION: Do not allow the grinding wheel to touch the aluminum heater tubes. 6. Remove the aluminum crimp band from the hose using expanding snap-ring pliers (Snap-on SRP5A or equivalent) (Figure 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Recalls for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 7468 7. Slide the spring clamps off of the heater core quick-connect fittings located on the rear heater core tubes (Figure 3). 8. Carefully remove both old heater hoses from the heater tubes. CAUTION: Residual coolant will come out of the hoses and tubes when the heater hoses are removed. Use an appropriate container to catch the coolant. 9. Remove and save the spring clamps on the old hoses. Then discard the old hoses. 10. Install two spring clamps onto each heater tube. 11. Using the short hoses supplied in the kit, install the new heater hoses onto the heater hose tubes and the heater core tube quick connects. 12. Place the spring clamps at each end of the new heater hose. NOTE: The wings of the spring clamps should be pointed downward. 13. Remove the spare tire heat shields to gain access to the front set of heater hoses. 14. Using a cut off wheel, grind a slot into the heater tube aluminum crimp band on the two heater hoses (Figure 4). CAUTION: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Recalls for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 7469 Do not allow the grinding wheel to touch the aluminum heater tubes. 15. Remove the aluminum crimp band from the hose using expanding snap-ring pliers (Snap-on SRP5A or equivalent) (Figure 2). 16. Slide the spring clamps off the heater hoses (Figure 3). 17. Remove the heater hoses from the vehicle. 18. Remove and save the spring clamps on the old hoses. Then discard the old hoses 19. Install two spring clamps onto each heater tube. 20. Using the long hoses supplied in the kit, install the new heater hoses onto the heater hose tubes. 21. Place the spring clamps at each end of the new heater hose. NOTE: The wings of the spring clamp should be pointed downward. 22. Install the tire heat shields. 23. Lower the vehicle. 24. Remove the pinch-off pliers on the heater hoses in the engine compartment. 25. Raise the spare tire into position using the crank handle inside the vehicle. 26. Check the engine coolant level and add coolant as required. 27. Start the engine and ensure that the new heater hoses do not leak. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Recalls for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 7470 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement Technical Service Bulletin # F06 Date: 060401 Campaign - Underbody Heater Hose Replacement April 2006 Dealer Service Instructions for: Customer Satisfaction Notification F06 Underbody Heater Hoses Effective immediately, all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 05-028 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2005 (RS) Dodge Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles equipped with rear Heater/Air Conditioning (sales code HBB) and Stow-n-Go seats (sales code CYC) or Stow-N-Go floor pan (sales code CYY or CYV). IMPORTANT: The above vehicles located in the "salt belt" are involved in Customer Satisfaction Notification F01 (Rear A/C Heater tube Corrosion) and therefore have been excluded from this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The underbody heater hoses on about 141,000 of the above vehicles may leak coolant at the heater tube crimps. This may result in the engine overheating. Engine damage can occur if an overheated engine continues to be driven. Repair The underbody heater hoses for the rear heater must be replaced. Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 7476 Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the hood. 2. Lower the spare tire using the crank handle inside the vehicle (approximately 10 turns). 3. Using pinch-off pliers, clamp off the heater hoses in the engine compartment that connect the rear heater tubes to the engine cooling system. 4. Lift the vehicle on an appropriate hoist. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 7477 5. Using a cut off wheel, grind a slot into the heater tube aluminum crimp band on the two rear heater hoses (Figure 1). CAUTION: Do not allow the grinding wheel to touch the aluminum heater tubes. 6. Remove the aluminum crimp band from the hose using expanding snap-ring pliers (Snap-on SRP5A or equivalent) (Figure 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 7478 7. Slide the spring clamps off of the heater core quick-connect fittings located on the rear heater core tubes (Figure 3). 8. Carefully remove both old heater hoses from the heater tubes. CAUTION: Residual coolant will come out of the hoses and tubes when the heater hoses are removed. Use an appropriate container to catch the coolant. 9. Remove and save the spring clamps on the old hoses. Then discard the old hoses. 10. Install two spring clamps onto each heater tube. 11. Using the short hoses supplied in the kit, install the new heater hoses onto the heater hose tubes and the heater core tube quick connects. 12. Place the spring clamps at each end of the new heater hose. NOTE: The wings of the spring clamps should be pointed downward. 13. Remove the spare tire heat shields to gain access to the front set of heater hoses. 14. Using a cut off wheel, grind a slot into the heater tube aluminum crimp band on the two heater hoses (Figure 4). CAUTION: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 7479 Do not allow the grinding wheel to touch the aluminum heater tubes. 15. Remove the aluminum crimp band from the hose using expanding snap-ring pliers (Snap-on SRP5A or equivalent) (Figure 2). 16. Slide the spring clamps off the heater hoses (Figure 3). 17. Remove the heater hoses from the vehicle. 18. Remove and save the spring clamps on the old hoses. Then discard the old hoses 19. Install two spring clamps onto each heater tube. 20. Using the long hoses supplied in the kit, install the new heater hoses onto the heater hose tubes. 21. Place the spring clamps at each end of the new heater hose. NOTE: The wings of the spring clamp should be pointed downward. 22. Install the tire heat shields. 23. Lower the vehicle. 24. Remove the pinch-off pliers on the heater hoses in the engine compartment. 25. Raise the spare tire into position using the crank handle inside the vehicle. 26. Check the engine coolant level and add coolant as required. 27. Start the engine and ensure that the new heater hoses do not leak. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > F06 > Apr > 06 > Campaign - Underbody Heater Hose Replacement > Page 7480 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front Heater Hose: Service and Repair Front Heater Inlet Hose REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The heater inlet hose is constructed from formed steel tubing and rubber hoses. Depending on application, the ends are secured to the heater core, engine oil cooler or the engine by spring tension clamps. 1. Drain the engine cooling system. Heater Inlet Hose - 2.4L Shown, 2.5L Typical Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front > Page 7483 Heater Inlet Hose - 3.3L/3.8L W/O Rear Heater Heater Inlet Hose - 3.3L/3.8L With Rear Heater 2. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes/heater core, causing an engine coolant leak. 3. Disconnect each hose end by carefully twisting the hose back and forth on the tube or nipple, while gently pulling it away from the end of the tube or nipple. NOTE: Replacement of the heater inlet hoses will be required if the hose ends are cut for removal. 4. If necessary, carefully cut the hose end and peel the hose off of the tube or nipple. INSTALLATION 1. Using spring tension clamp pliers, compress and slide each clamp away from the end of the hose being installed. 2. Install each hose by carefully twisting the hose back and forth while gently pushing it onto the tube or nipple end. 3. Using spring tension clamp pliers, compress and slide the clamps onto each end of the hose being installed. 4. Refill the engine cooling system. Heater Return Hose REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The heater return tube is constructed from formed steel tubing and rubber hoses. Depending on application, the ends are secured to the heater core, engine oil cooler or the engine by spring tension clamps. 1. Drain the engine cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front > Page 7484 Heater Return Hose - 2.4L Shown, 2.5L Typical Heater Return Hose - 3.3L/3.8L W/O Rear Heater Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front > Page 7485 Heater Hoses - 3.3/3.8L With Rear Heater 2. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes/heater core, causing an engine coolant leak. 3. Disconnect each hose end by carefully twisting the hose back and forth on the tube or nipple, while gently pulling it away from the end of the tube or nipple. NOTE: Replacement of the heater return hoses will be required if the hose ends are cut for removal. 4. If necessary, carefully cut the hose end and peel the hose off of the tube or nipple. INSTALLATION 1. Using spring tension clamp pliers, compress and slide the clamp away from the end of the heater return hose. 2. Install each hose end by carefully twisting the hose back and forth while gently pushing it onto the tube. 3. Using spring tension clamp pliers, compress and slide the clamps onto each end of the heater return hose. 4. Refill the engine cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Front > Page 7486 Heater Hose: Service and Repair Rear Heater Hoses REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Drain the engine cooling system. 2. Raise and support the vehicle. 3. Using spring tension clamp pliers, compress and slide the clamps off of each end of the hose being removed. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes, causing an engine coolant leak. Underbody Heater Hose Connections - Front 4. Disconnect the front underbody heater inlet and return hose by carefully twisting the hoses back and forth on the underbody tubes, while gently pulling them away from the end of the tubes. 5. If necessary, carefully cut the hose ends and peel the hoses off of the tubes. NOTE: Replacement of the heater hoses will be required if the hose ends are cut for removal. INSTALLATION 1. Install the front underbody heater inlet and return hoses by carefully twisting the hoses back and forth on the underbody tubes, while gently pushing them onto the end of the tubes. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes, causing an engine coolant leak. 2. Using spring tension clamp pliers, compress and slide the clamps that secure each end of the heater hose over the tubes. Release the clamp when it is over the tube. 3. Lower the vehicle. 4. Refill the engine cooling system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Recalls for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion Technical Service Bulletin # F01 Date: 060201 Campaign - Rear A/C/Heater Tube Corrosion February 2006 Dealer Service Instructions for: Customer Satisfaction Notification F01 Rear A/C and Heater Tube Corrosion Effective immediately all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 05-028 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2005 (RS) Dodge Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles equipped with rear Heater/Air Conditioning (sales code HBB) and Stow-n-Go seats (sales code CYC) or Stow-N-Go floor pan (sales code CYY or CYV). IMPORTANT: Only the above vehicles sold or currently registered in "salt belt" states (where large amounts of road salt are used for snow and ice removal) are involved. See "Owner Notification and Service Scheduling" section for a list of salt belt states. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The underbody rear A/C and heater tube mounting brackets on about 239,800 of the above vehicles may have insufficient corrosion protection. Excessive corrosion can cause the rear A/C or heater tubes to leak. This may result in either an inoperative A/C system or engine overheating. Engine damage can occur if an overheated engine continues to be driven. Repair The underbody rear A/C and heater tube assembly must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Recalls for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 7495 Parts Information Completion Reporting and Reimbursement DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Only vehicles sold or currently registered in "Salt Belt" states (where large amounts of road salt are used for snow and ice removal) are involved. The Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Recalls for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 7496 following states are "Salt Belt" states: Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the hood. 2. Using an approved refrigerant recovery machine, recover the refrigerant from the air conditioning system. Follow the manufacturers instructions provided with the machine being used. 3. Using a suitable clean container, drain the coolant from the engine cooling system. Save the coolant for reuse. 4. Raise the vehicle on an appropriate hoist. 5. Disconnect the exhaust system from the exhaust hanger rubber isolators and position the exhaust system out of the way. 6. Disconnect the underbody A/C lines from the front liquid and suction line extension tubes (Figure 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Recalls for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 7497 7. Remove the nut that secures the underbody A/C lines to the rear evaporator tapping plate (Figure 2). 8. Disconnect the underbody A/C lines from the evaporator tapping plate. NOTE: The A/C line mounting block may not come loose after removing the retaining nut due to corrosion between the mounting block and the retaining stud. Do not use excessive force to attempt to remove the mounting block from the evaporator. Evaporator damage may occur. Using an air chisel with a flat nose bit, gently pull down on the A/C lines and then lightly rap on the end of the stud with the bit of the air chisel (Figure 3). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Recalls for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 7498 9. Remove the fasteners that secure the four underbody line retaining straps to the vehicles underbody (Figure 4). 10. Remove the fastener that secures the right rear brake line bracket to the underbody (Figure 5). 11. Disconnect the underbody heater tubes at the rear of the vehicle by releasing the insert in the underbody heater tube quick connect fittings and Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Recalls for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 7499 carefully pull downward on the heater tube fitting. CAUTION: Residual coolant will come out of the heater hoses when they are removed. Be prepared to catch the residual coolant in a suitable container. 12. Lower the underbody heater tubes to drain any residual coolant from the tubes. 13. Using spring tension clamp pliers (Blue Point(R) YA9562 or equivalent), compress and slide the clamps off the rubber hoses at the front of the underbody coolant tubes. 14. Disconnect the heater hoses by carefully twisting the hoses back and forth while gently pulling them away from the end of the coolant tubes. 15. Remove and discard the underbody rear A/C and heater tubes. 16. Using locking pliers, remove and discard the stud from the evaporator tapping plate. CAUTION: Failure to replace the stud will cause future A/C tube failure. The new stud has an additional coating to prevent corrosion. 17. Using an E7 Torx(R) socket (Snap-on(R) TLE70A or equivalent), install the new stud provided in the kit into the evaporator tapping plate (Figure 6). Tighten the stud to 80 in. lbs. (9 N.m). 18. Remove the plastic shipping cap on the A/C mounting block and pour 1 oz. of PAG oil (P/N 82300102) into the A/C suction line. Then temporarily reinstall the shipping cap. 19. Position the new line kit under the vehicle and install the fasteners that secure the four retaining straps to the vehicle. Tighten the fasteners to 65 in. lbs. (7 N.m). 20. Position the rear brake line bracket and install the fastener. Tighten the fastener to 250 in. lbs. (28 N.m). 21. Remove and discard the plastic shipping cap from the A/C mounting block and lubricate the new o-ring seals with clean refrigerant oil. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Recalls for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 7500 22 Connect the underbody A/C lines to the rear evaporator tapping plate (Figure 7). 23. Install the new nut/washer, provided in the kit, to secure the underbody A/C line mounting block to the rear evaporator tapping plate (Figure 7). Tighten the nut to 17 ft. lbs. (23 N.m). 24. Remove the plastic shipping caps and lubricate the new o-ring seals for front extension tubes with clean refrigerant oil. 25. Connect the underbody A/C line fittings to the front liquid and suction line extension tubes. Tighten the A/C line brass nuts to 17 ft. lbs. (23 N.m). 26. Connect the rubber hoses at the front of the underbody heater tube hoses to the rear heater extension tubes. 27. Using spring tension clamp pliers (Blue Point® YA9562 or equivalent), compress and slide the clamps that secure the heater hoses over the extension tubes. Release the clamp when it is correctly positioned over the tube. 28. Connect the rear underbody heater quick connect fittings to the rear heater core extension tubes. 29. Place the exhaust system into position and attach the exhaust hanger rubber isolators. 30. Lower the vehicle from the hoist. 31. Using an approved refrigerant evacuation machine, evacuate the A/C system. Follow the manufacturers instructions provided with the machine being used. 32. Refill the engine cooling system using the original coolant removed from the vehicle. 33. Using an approved refrigerant charging machine, charge the A/C system. Follow the manufacturers instructions provided with the machine being used. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Recalls for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 7501 NOTE: Refer to the underhood A/C charge label for the correct amount of refrigerant to install into the A/C system (Figure 8). 34. Remove the A/C charging machine, close the hood and return the vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Recalls for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 7502 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion Technical Service Bulletin # F01 Date: 060201 Campaign - Rear A/C/Heater Tube Corrosion February 2006 Dealer Service Instructions for: Customer Satisfaction Notification F01 Rear A/C and Heater Tube Corrosion Effective immediately all repairs on involved vehicles are to be performed according to this notification. Rapid Response Transmittal (RRT) # 05-028 is being cancelled. Those vehicles that have already had this repair performed, as determined by our warranty records, have been excluded from this notification. Models 2005 (RS) Dodge Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles equipped with rear Heater/Air Conditioning (sales code HBB) and Stow-n-Go seats (sales code CYC) or Stow-N-Go floor pan (sales code CYY or CYV). IMPORTANT: Only the above vehicles sold or currently registered in "salt belt" states (where large amounts of road salt are used for snow and ice removal) are involved. See "Owner Notification and Service Scheduling" section for a list of salt belt states. IMPORTANT: Some of the involved vehicles may be in dealer vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The underbody rear A/C and heater tube mounting brackets on about 239,800 of the above vehicles may have insufficient corrosion protection. Excessive corrosion can cause the rear A/C or heater tubes to leak. This may result in either an inoperative A/C system or engine overheating. Engine damage can occur if an overheated engine continues to be driven. Repair The underbody rear A/C and heater tube assembly must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 7508 Parts Information Completion Reporting and Reimbursement DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Use the labor operation number and time allowance shown. Add the cost of the parts package plus applicable dealer allowance to your claim. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification All dealers will receive a copy of this dealer notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Only vehicles sold or currently registered in "Salt Belt" states (where large amounts of road salt are used for snow and ice removal) are involved. The Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 7509 following states are "Salt Belt" states: Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure 1. Open the hood. 2. Using an approved refrigerant recovery machine, recover the refrigerant from the air conditioning system. Follow the manufacturers instructions provided with the machine being used. 3. Using a suitable clean container, drain the coolant from the engine cooling system. Save the coolant for reuse. 4. Raise the vehicle on an appropriate hoist. 5. Disconnect the exhaust system from the exhaust hanger rubber isolators and position the exhaust system out of the way. 6. Disconnect the underbody A/C lines from the front liquid and suction line extension tubes (Figure 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 7510 7. Remove the nut that secures the underbody A/C lines to the rear evaporator tapping plate (Figure 2). 8. Disconnect the underbody A/C lines from the evaporator tapping plate. NOTE: The A/C line mounting block may not come loose after removing the retaining nut due to corrosion between the mounting block and the retaining stud. Do not use excessive force to attempt to remove the mounting block from the evaporator. Evaporator damage may occur. Using an air chisel with a flat nose bit, gently pull down on the A/C lines and then lightly rap on the end of the stud with the bit of the air chisel (Figure 3). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 7511 9. Remove the fasteners that secure the four underbody line retaining straps to the vehicles underbody (Figure 4). 10. Remove the fastener that secures the right rear brake line bracket to the underbody (Figure 5). 11. Disconnect the underbody heater tubes at the rear of the vehicle by releasing the insert in the underbody heater tube quick connect fittings and Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 7512 carefully pull downward on the heater tube fitting. CAUTION: Residual coolant will come out of the heater hoses when they are removed. Be prepared to catch the residual coolant in a suitable container. 12. Lower the underbody heater tubes to drain any residual coolant from the tubes. 13. Using spring tension clamp pliers (Blue Point(R) YA9562 or equivalent), compress and slide the clamps off the rubber hoses at the front of the underbody coolant tubes. 14. Disconnect the heater hoses by carefully twisting the hoses back and forth while gently pulling them away from the end of the coolant tubes. 15. Remove and discard the underbody rear A/C and heater tubes. 16. Using locking pliers, remove and discard the stud from the evaporator tapping plate. CAUTION: Failure to replace the stud will cause future A/C tube failure. The new stud has an additional coating to prevent corrosion. 17. Using an E7 Torx(R) socket (Snap-on(R) TLE70A or equivalent), install the new stud provided in the kit into the evaporator tapping plate (Figure 6). Tighten the stud to 80 in. lbs. (9 N.m). 18. Remove the plastic shipping cap on the A/C mounting block and pour 1 oz. of PAG oil (P/N 82300102) into the A/C suction line. Then temporarily reinstall the shipping cap. 19. Position the new line kit under the vehicle and install the fasteners that secure the four retaining straps to the vehicle. Tighten the fasteners to 65 in. lbs. (7 N.m). 20. Position the rear brake line bracket and install the fastener. Tighten the fastener to 250 in. lbs. (28 N.m). 21. Remove and discard the plastic shipping cap from the A/C mounting block and lubricate the new o-ring seals with clean refrigerant oil. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 7513 22 Connect the underbody A/C lines to the rear evaporator tapping plate (Figure 7). 23. Install the new nut/washer, provided in the kit, to secure the underbody A/C line mounting block to the rear evaporator tapping plate (Figure 7). Tighten the nut to 17 ft. lbs. (23 N.m). 24. Remove the plastic shipping caps and lubricate the new o-ring seals for front extension tubes with clean refrigerant oil. 25. Connect the underbody A/C line fittings to the front liquid and suction line extension tubes. Tighten the A/C line brass nuts to 17 ft. lbs. (23 N.m). 26. Connect the rubber hoses at the front of the underbody heater tube hoses to the rear heater extension tubes. 27. Using spring tension clamp pliers (Blue Point® YA9562 or equivalent), compress and slide the clamps that secure the heater hoses over the extension tubes. Release the clamp when it is correctly positioned over the tube. 28. Connect the rear underbody heater quick connect fittings to the rear heater core extension tubes. 29. Place the exhaust system into position and attach the exhaust hanger rubber isolators. 30. Lower the vehicle from the hoist. 31. Using an approved refrigerant evacuation machine, evacuate the A/C system. Follow the manufacturers instructions provided with the machine being used. 32. Refill the engine cooling system using the original coolant removed from the vehicle. 33. Using an approved refrigerant charging machine, charge the A/C system. Follow the manufacturers instructions provided with the machine being used. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 7514 NOTE: Refer to the underhood A/C charge label for the correct amount of refrigerant to install into the A/C system (Figure 8). 34. Remove the A/C charging machine, close the hood and return the vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > F01 > Feb > 06 > Campaign - Rear A/C/Heater Tube Corrosion > Page 7515 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Page 7516 Hose/Line HVAC: Service Precautions WARNING: - THE A/C SYSTEM CONTAINS REFRIGERANT UNDER HIGH PRESSURE. REPAIRS SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL. SEVERE PERSONAL INJURY OR DEATH MAY RESULT FROM IMPROPER SERVICE PROCEDURES. - AVOID BREATHING THE REFRIGERANT AND REFRIGERANT OIL VAPOR OR MIST. EXPOSURE MAY IRRITATE THE EYES, NOSE, AND/OR THROAT. WEAR EYE PROTECTION WHEN SERVICING THE A/C REFRIGERANT SYSTEM. SERIOUS EYE INJURY CAN RESULT FROM DIRECT CONTACT WITH THE REFRIGERANT. IF EYE CONTACT OCCURS, SEEK MEDICAL ATTENTION IMMEDIATELY. - DO NOT EXPOSE THE REFRIGERANT TO OPEN FLAME. POISONOUS GAS IS CREATED WHEN REFRIGERANT IS BURNED. AN ELECTRONIC LEAK DETECTOR IS RECOMMENDED. SEVERE PERSONAL INJURY OR DEATH MAY RESULT FROM IMPROPER SERVICE PROCEDURES. - IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE THE WORK AREA BEFORE RESUMING SERVICE. LARGE AMOUNTS OF REFRIGERANT RELEASED IN A CLOSED WORK AREA WILL DISPLACE THE OXYGEN AND CAUSE SUFFOCATION AND DEATH. - THE EVAPORATION RATE OF R-134A REFRIGERANT AT AVERAGE TEMPERATURE AND ALTITUDE IS EXTREMELY HIGH. AS A RESULT, ANYTHING THAT COMES IN CONTACT WITH THE REFRIGERANT WILL FREEZE. ALWAYS PROTECT THE SKIN OR DELICATE OBJECTS FROM DIRECT CONTACT WITH THE REFRIGERANT. - THE R-134A SERVICE EQUIPMENT OR THE VEHICLE REFRIGERANT SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR AND R-134A HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS, AND MAY RESULT IN FIRE OR EXPLOSION CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. - THE ENGINE COOLING SYSTEM IS DESIGNED TO DEVELOP INTERNAL PRESSURES OF 97 TO 123 KILOPASCALS (14 TO 18 POUNDS PER SQUARE INCH). DO NOT REMOVE OR LOOSEN THE COOLANT PRESSURE CAP, CYLINDER BLOCK DRAIN PLUGS, RADIATOR DRAIN, RADIATOR HOSES, HEATER HOSES, OR HOSE CLAMPS WHILE THE ENGINE COOLING SYSTEM IS HOT AND UNDER PRESSURE. ALLOW THE VEHICLE TO COOL FOR A MINIMUM OF 15 MINUTES BEFORE OPENING THE COOLING SYSTEM FOR SERVICE. FAILURE TO OBSERVE THIS WARNING CAN RESULT IN SERIOUS BURNS FROM THE HEATED ENGINE COOLANT. CAUTION: - Never add R-12 to a refrigerant system designed to use R-134a. Do not use R-12 equipment or parts on a R-134a A/C system. These refrigerants are not compatible and damage to the A/C system will result. - Never use R-12 refrigerant oil in a A/C system designed to use R-134a refrigerant oil. These refrigerant oils are not compatible and damage to the A/C system will result. - The use of A/C system sealers may result in damage to A/C refrigerant recovery/evacuation/recharging equipment and/or A/C system. Many federal, state/provincial and local regulations prohibit the recharge of A/C systems with known leaks. DaimlerChrysler recommends the detection of A/C system leaks through the use of approved leak detectors and fluorescent leak detection dyes. Vehicles found with A/C system sealers should be treated as contaminated and replacement of the entire A/C refrigerant system is recommended. A/C systems found to be contaminated with A/C system sealers, A/C stop-leak products or seal conditioners voids the warranty for the A/C system. - Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. - If equipped, do not remove the secondary retention clip from any spring-lock coupler connection while the refrigerant system is under pressure. Recover the refrigerant before removing the secondary retention clip. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. - The internal parts of the A/C system will remain stable as long as moisture-free refrigerant and refrigerant oil is used. Abnormal amounts of dirt, moisture or air can upset the chemical stability. This may cause operational troubles or even serious damage if present in more than very small quantities. Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system. Keep service tools and the work area clean. Do not open the refrigerant system or uncap a replacement component until you are ready to service the system. Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug. This will prevent contamination from entering the A/C system. - Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a container of refrigerant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container. - Do not overcharge the refrigerant system. Overcharging will cause excessive compressor head pressure and can cause compressor noise and A/C system failure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Plumbing Hose/Line HVAC: Description and Operation Plumbing The A/C refrigerant lines and hoses are used to carry the refrigerant between the various A/C system components. The refrigerant lines and hoses for the R-134a system on this vehicle consist of a barrier-hose design with a nylon tube sandwiched between rubber layers. The nylon tube helps to contain the R-134a refrigerant, which has a smaller molecular structure than R-12 refrigerant. The ends of the refrigerant lines are made from lightweight aluminum or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant lines and hoses will reduce the capacity of the entire A/C system and can reduce the flow of refrigerant in the system. The radius of all bends in the flexible hose refrigerant lines should be at least ten times the diameter of the hose and the refrigerant lines should be routed so they are at least 80 millimeters (3 inches) away from the exhaust manifold(s) and exhaust pipe(s). High pressures are produced in the refrigerant system when the A/C compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed. The refrigerant lines and hoses are coupled to other A/C system components with block-type fittings. An O-ring seal, or a flat steel gasket with an integral O-ring (dual plane seal), is used to mate the refrigerant line fittings with A/C system components to ensure the integrity of the refrigerant system. The refrigerant lines and hoses cannot be repaired and, if faulty or damaged, they must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Plumbing > Page 7519 Hose/Line HVAC: Description and Operation Underbody Lines Rear Heater And A/C Lines - Typical Underbody lines are used on models equipped with the rear heating-A/C system. The underbody suction line, liquid line, and heater tubes can each be serviced separately. Rear Heater And A/C Lines - Typical Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Plumbing > Page 7520 Front Extension Lines To Underbody Lines - Typical The rear heating-A/C underbody lines are all serviced as individual components. When disconnecting any line or connection, make sure that the area around the line or connection is clean of any dirt or residue that may enter and contaminate the rear heating-A/C system. WARNING: HIGH PRESSURES ARE PRODUCED IN THE REFRIGERANT SYSTEM WHEN THE A/C COMPRESSOR IS OPERATING. HIGH TEMPERATURE COOLANT IS PRESENT IN THE HEATER PLUMBING WHEN THE ENGINE IS OPERATING. EXTREME CARE MUST BE EXERCISED WHEN SERVICING THE REAR HEATER AND A/C LINES TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH. Any kinks or sharp bends in the rear heater-A/C plumbing will reduce the capacity of the entire heating-A/C system. Kinks and sharp bends reduce the system flow. High pressures are produced in the refrigerant system when the A/C compressor is operating. High temperature coolant is present in the heater plumbing when the engine is operating. Extreme care must be exercised to make sure that each of the connections is pressure-tight and leak free. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > Page 7521 Hose/Line HVAC: Testing and Inspection REFRIGERANT SYSTEM LEAKS WARNING: R-134A SERVICE EQUIPMENT OR VEHICLE A/C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. MIXTURE OF AIR AND R-134A CAN BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. AVOID BREATHING A/C REFRIGERANT AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY IRRITATE EYES, NOSE AND THROAT. USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO DISCHARGE R-134A SYSTEM. IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE WORK AREA BEFORE RESUMING SERVICE. If the A/C system is not cooling properly, determine if the refrigerant system is fully charged with R-134a. If while performing this test A/C liquid line pressure is less than 345 kPa (50 psi) proceed to System Empty procedure. If liquid line pressure is greater than 345 kPa (50 psi) proceed to System Low procedure. If the refrigerant system is empty or low in refrigerant charge, a leak at any line fitting or component seal is likely. A review of the fittings, lines and components for oily residue is an indication of the leak location. To detect a leak in the refrigerant system, perform one of the following procedures as indicated by the results of the refrigerant system charge level test. SYSTEM EMPTY 1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approx. 28 in Hg.). Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed with this procedure. 2. Prepare a 0.284 Kg. (10 oz.) refrigerant charge to be injected into the system. 3. Connect and dispense 0.284 Kg. (10 oz.) of refrigerant into the evacuated refrigerant system. 4. Proceed to the SYSTEM LOW procedures. SYSTEM LOW 1. Position the vehicle in a wind-free work area. This will aid in detecting small leaks. 2. Bring the refrigerant system up to operating temperature and pressure. This is done by allowing the engine to run for five minutes with the system set to the following: Transaxle in Park - Engine idling - Rear A/C Off (if equipped) - A/C controls set to 100 percent outside air - Blower switch in the highest speed position - A/C in the On position - Front windows open CAUTION: A leak detector designed for R-12 refrigerant (only) will not detect leaks in a R-134a refrigerant system. 3. Shut off the vehicle and wait 2 to 7 minutes. Then use an electronic leak detector that is designed to detect R-134a type refrigerant and search for leaks. Fittings, lines, or components that appear to be oily usually indicates a refrigerant leak. To inspect the evaporator core for leaks, insert the leak detector probe into the drain tube opening or a heat duct. A R-134a dye is available to aid in leak detection, use only DaimlerChrysler approved refrigerant dye. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line Hose/Line HVAC: Service and Repair A/C Discharge Line REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Remove the right headlamp unit. A/C Discharge Line To A/C Condenser - Typical 3. Remove the nut that secures the A/C discharge line to the right end of the A/C condenser. 4. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket. 5. Install plugs in, or tape over the opened discharge line fitting and the condenser inlet port. 6. Raise and support the vehicle. 7. On models equipped with the 2.5L and 2.8L diesel engines, remove the belly pan from underneath the engine compartment. A/C Discharge Line To Compressor - Typical Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7524 8. Remove the nut that secures the A/C discharge line to the A/C compressor. 9. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring seal and gasket. 10. Install plugs in, or tape over the opened discharge line fitting and the compressor discharge port. 11. Remove the A/C discharge line from the engine compartment. INSTALLATION 1. Position the A/C discharge line into the engine compartment. 2. Remove the tape or plugs from the compressor discharge port and the discharge line fitting. 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. 4. Install the A/C discharge line to the A/C compressor. 5. Install the nut that secures the A/C discharge line to the A/C compressor. Tighten the nut to 23 N.m (17 ft. lbs.). 6. On models with the 2.5L and 2.8L diesel engine, install the belly pan. 7. Lower the vehicle. 8. Remove the tape or plugs from the condenser inlet port and the discharge line fitting. 9. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. 10. Install the A/C discharge line to the A/C condenser. 11. Install the nut that secures the A/C discharge line to the A/C condenser. Tighten the nut to 23 N.m (17 ft. lbs.). 12. Install the right headlamp unit. 13. Evacuate the refrigerant system. 14. Charge the refrigerant system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7525 Hose/Line HVAC: Service and Repair Liquid Line Front Section WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The front A/C liquid line is serviced in two sections. The front connects between the A/C condenser and the receiver/drier and includes the high side service port. The rear connects between the receiver/drier and the A/C expansion valve and includes the fitting for the A/C pressure transducer. On models equipped with the rear heating-A/C system, the rear of the front A/C liquid line also includes a hose and tube extension that connects the front liquid line to the liquid line for the rear A/C system. REMOVAL 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Remove the right headlamp unit. A/C Condenser - Typical 4. Remove the nut that secures the A/C liquid line to the right end of the A/C condenser. 5. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket. 6. Install plugs in, or tape over the opened liquid line fitting and the condenser outlet port. 7. Remove the air cleaner housing and the air inlet tube. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7526 A/C Liquid Line - LHD Shown, RHD Typical 8. Disengage the retainer that secures the liquid line routing clip to the top of the right frame rail ahead of the front strut tower in the engine compartment. 9. Remove the bolt that secures the front of the A/C liquid line to the receiver/drier. 10. Disconnect the A/C liquid line from the receiver/drier and remove and discard the O-ring seal. 11. Install plugs in, or tape over the opened liquid line fitting and the receiver/drier inlet port. INSTALLATION 1. Position the front of the A/C liquid line into the engine compartment. 2. Remove the tape or plugs from the liquid line fitting and the receiver/drier inlet port. 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it onto the liquid line fitting. 4. Connect the A/C liquid line to the receiver/ drier. 5. Install the bolt that secures the A/C liquid line to the receiver/drier. Tighten the bolt to 11 N.m (97 in. lbs.). 6. Engage the retainer that secures the liquid line routing clip to the top of the right frame rail ahead of the front strut tower in the engine compartment. 7. Install the air cleaner housing and air inlet tube. 8. Remove the tape or plugs from the condenser outlet port and the liquid line fitting. 9. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. 10. Connect the A/C liquid line to the A/C condenser. 11. Install the nut that secures the A/C liquid line to the A/C condenser. Tighten the nut to 23 N.m (17 ft. lbs.). 12. Install the right headlamp unit. 13. Reconnect the negative battery cable. 14. Evacuate the refrigerant system. 15. Charge the refrigerant system. Rear Section WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The front A/C liquid line is serviced in two sections. The front connects between the A/C condenser and the receiver/drier and includes the high Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7527 side service port. The rear connects between the receiver/drier and the A/C expansion valve and includes the fitting for the A/C pressure transducer. On models equipped with the rear heating-A/C system, the rear of the front A/C liquid line also includes a hose and tube extension that connects the front liquid line to the liquid line for the rear A/C system. REMOVAL 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Remove the air cleaner housing and the air inlet tube. 4. Disconnect the drain tube from the wiper module drain on the right side of the engine compartment. 5. Remove the A/C pressure transducer. A/C Liquid Line - LHD Shown, RHD Typical 6. If equipped, remove the nut that secures the A/C ground strap to the weld stud on the top of the right front strut tower. 7. If equipped, remove the A/C ground strap eyelet terminal connector from the weld stud. 8. Remove the bolt that secures the rear of the A/C liquid line to the receiver/drier. 9. Disconnect the A/C liquid line from the receiver/drier and remove and discard the O-ring seal. 10. Install plugs in, or tape over the opened liquid line fitting and the receiver/drier outlet port. 11. Remove the nut that secures the A/C suction line and the A/C liquid line to the A/C expansion valve. 12. Disconnect the A/C suction line and the A/C liquid line from the A/C expansion valve and remove and discard the O-ring seals. 13. Install plugs in, or tape over the opened suction line and liquid line fittings and both expansion valve ports. 14. On RHD models, remove the rear of the A/C liquid line from the retaining bracket located at the top of the dash panel 15. If the vehicle is equipped with the optional rear heating-A/C system, go to Step 16. If the vehicle is not equipped with the optional rear heating-A/C system, go to Step 22. 16. Raise and support the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7528 Underbody A/C Line Connections 17. Cut the tie strap located just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heating-A/C system. 18. Disconnect the A/C liquid line extension fitting from the underbody liquid line fitting for the rear A/C system. 19. Remove the O-ring seal from the underbody liquid line fitting and discard. 20. Install plugs in, or tape over the opened liquid line fittings. 21. Lower the vehicle. 22. Remove the rear of the A/C liquid line from the engine compartment. INSTALLATION 1. Position the rear of the A/C liquid line into the engine compartment. 2. Remove the tape or plugs from the suction line and liquid line fittings and both expansion valve ports. 3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the suction line and liquid line fittings. 4. Reconnect the A/C liquid line and the A/C suction line to the A/C expansion valve. 5. Install the nut that secures the rear of the A/C liquid line and the A/C suction line to the A/C expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.). 6. Remove the tape or plugs from the liquid line fitting and the receiver/drier outlet port. 7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting. 8. Reconnect the A/C liquid line to the receiver/ drier. 9. Install the bolt that secures the A/C liquid line to the receiver/drier. Tighten the bolt to 11 N.m (97 in. lbs.). 10. If equipped, reinstall the A/C ground strap eyelet terminal connector onto the weld stud on the top of the right front strut tower (if equipped). 11. If equipped, install the nut that secures the A/C ground strap to the weld stud. Tighten the nut to 12 N.m (106 in. lbs.). 12. Install the A/C pressure transducer. 13. Connect the drain tube to the wiper module drain on the right side of the engine compartment. 14. Install the air cleaner housing and air inlet tube. 15. On RHD models, install the liquid line into the retaining bracket located at the top of the dash panel. 16. If the vehicle is equipped with the optional rear heating-A/C system, go to Step 17. If the vehicle does not have the optional rear heating-A/C system, go to Step 23. 17. Raise and support the vehicle. 18. Remove the tape or plugs from the A/C liquid line extension fitting and the underbody liquid line fitting. 19. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the underbody liquid line fitting. 20. Connect the A/C liquid line extension fitting to the underbody liquid line fitting. Tighten the fittings to 23 N.m (17 ft. lbs.). 21. Install a new tie strap just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heating-A/C system. 22. Lower the vehicle. 23. Reconnect the negative battery cable. 24. Evacuate the refrigerant system. 25. Charge the refrigerant system. Rear REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7529 FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: On models equipped with the rear A/C system, the rear of the front A/C liquid line also includes a hose and tube extension that connects the front liquid line to the underbody liquid line. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Remove the air cleaner housing from the right side of the engine compartment. 4. Disconnect the drain tube from the wiper module drain on the right side of the engine compartment. 5. Remove the A/C pressure transducer. Liquid Line 6. If equipped, remove the nut that secures the A/C ground strap to the weld stud on the top of the right front strut tower. 7. If equipped, remove the A/C ground strap eyelet terminal connector from the weld stud. 8. Remove the bolt that secures the rear of the front liquid line to the top of the receiver/drier. 9. Disconnect the rear of the front liquid line from the top of the receiver/drier and remove and discard the O-ring seal. 10. Install plugs in, or tape over the opened liquid line fitting and the receiver/drier port. 11. Remove the nut that secures the suction and liquid line to the A/C expansion valve. 12. Disconnect the suction line and liquid lines from the A/C expansion valve and remove and discard the seals. 13. Install plugs in, or tape over the opened suction and liquid line fittings and expansion valve ports. 14. Raise and support the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7530 Underbody A/C Line Front Connections - Typical 15. Remove the tie strap and disconnect the front liquid line from the underbody liquid line and remove and discard the O-ring seal. 16. Install plugs in, or tape over the opened liquid line fittings. 17. Lower the vehicle. 18. Remove the liquid line from the engine compartment. INSTALLATION 1. Position the rear of the front liquid line into the engine compartment. 2. Remove the tape or plugs from the suction and liquid line fittings and expansion valve ports. 3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the suction and liquid line fittings. 4. Connect the suction and liquid lines to the A/C expansion valve. 5. Install the nut that secures the suction and liquid lines to the A/C expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.). 6. Remove the tape or plugs from the liquid line fitting for the receiver/drier and the receiver/drier port. 7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting. 8. Reconnect the liquid line to the receiver/drier. 9. Install the bolt that secures the liquid line to the receiver/drier. Tighten the bolt to 11 N.m (97 in. lbs.). 10. If equipped, reinstall the A/C ground strap eyelet terminal connector onto the weld stud on the top of the right front strut tower (if equipped). 11. If equipped, install the nut that secures the A/C ground strap to the weld stud. Tighten the nut to 12 N.m (106 in. lbs.). 12. Install the A/C pressure transducer. 13. Connect the drain tube to the wiper module drain on the right side of the engine compartment. 14. Install the air cleaner housing into the right side of the engine compartment. 15. Raise and support the vehicle. 16. Remove the tape or plugs from the liquid line rear extension fitting and the underbody liquid line. 17. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the underbody liquid line. 18. Connect the liquid line rear extension fitting to the underbody liquid line. Tighten the fittings to 23 N.m (17 ft. lbs.). 19. Install a new tie strap just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heating-A/C system. 20. Lower the vehicle. 21. Reconnect the negative battery cable. 22. Evacuate the refrigerant system. 23. Charge the refrigerant system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7531 Hose/Line HVAC: Service and Repair Suction Line Front REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The front suction line includes the low side service port near the A/C compressor. On models equipped with the rear A/C system, the front suction line also includes a suction line hose and tube extension that connects the front suction line to the suction line for the rear A/C system. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Remove the air cleaner top cover and snorkel from the air cleaner housing located on the right side of the engine compartment. 4. Disconnect the drain tube from the wiper module drain on the right side of the engine compartment. 5. Remove the nut that secures the suction line fitting to the top of the A/C compressor. 6. Disconnect the suction line fitting from the compressor suction port and remove and discard the O-ring seal. 7. Install plugs in, or tape over the opened suction line fitting and the compressor suction port. Suction Line - LHD Shown, RHD Typical 8. Remove the retainer that secures the suction line routing clip to the receiver/drier mounting bracket on the side of the right front strut tower in the engine compartment. 9. Remove the nut that secures the suction line and liquid line fittings to the A/C expansion valve. 10. Disconnect the suction line and liquid line fittings from the expansion valve and remove and discard the seals. 11. Install plugs in, or tape over the opened suction line and liquid line fittings and both expansion valve ports. 12. Remove the suction line from the retaining bracket located at the top of the dash panel. 13. If the vehicle is equipped with the rear heating-A/C system, go to Step 14. If the vehicle does not have the rear heating-A/C system, go to Step 19. 14. Raise and support the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7532 Underbody A/C Line Connections 15. Cut the tie strap located just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heating-A/C system. 16. Disconnect the suction line extension fitting from the underbody suction line fitting for the rear A/C system and remove and discard the O-ring seal. 17. Install plugs in, or tape over the opened suction line fittings. 18. Lower the vehicle. 19. Remove the suction line from the engine compartment. INSTALLATION 1. Position the suction line into the engine compartment. 2. Remove the tape or plugs from the suction line and liquid line fittings and both expansion valve ports. 3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the suction line and liquid line fittings. 4. Reconnect the liquid line and suction line fittings to the expansion valve. 5. Install the nut that secures the suction line and liquid line fittings to the expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.). 6. Install the retainer that secures the suction line routing clip to the receiver/drier mounting bracket on the side of the right front strut tower in the engine compartment. 7. Remove the tape or plugs from the compressor suction port and the suction line fitting. 8. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the suction line fitting. 9. Install a new dual plan seal and reconnect the suction line fitting to the compressor suction port. 10. Install the nut that secures the suction line fitting to the A/C compressor. Tighten the nut to 23 N.m (17 ft. lbs.). 11. Reconnect the drain tube to the wiper module drain on the right side of the engine compartment. 12. Install the air cleaner top cover and snorkel onto the air cleaner housing located on the right side of the engine compartment. 13. On RHD models, install the suction line into the retaining bracket located at the top of the dash panel. 14. If the vehicle is equipped with the rear heating-A/C system, go to Step 15. If the vehicle does not have the rear heating-A/C system, go to Step 21. 15. Raise and support the vehicle. 16. Remove the tape or plugs from the suction line extension fitting and the underbody suction line fitting. 17. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the underbody suction line fitting. 18. Reconnect the suction line extension fitting to the underbody suction line fitting. Tighten the fittings to 23 N.m (17 ft. lbs.). 19. Install a new tie strap just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heating-A/C system. 20. Lower the vehicle. 21. Reconnect the negative battery cable. 22. Evacuate the refrigerant system. 23. Charge the refrigerant system. Rear REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7533 NOTE: On models equipped with the rear A/C system, the rear of the front A/C suction line also includes a hose and tube extension that connects the front suction line to the underbody suction line. 1. Recover the refrigerant from the refrigerant system. 2. Disconnect and isolate the negative battery cable. 3. Remove the air cleaner top cover and snorkel from the air cleaner housing located on the right side of the engine compartment. 4. Disconnect the drain tube from the wiper module drain on the right side of the engine compartment. 5. Remove the nut that secures the suction line to the A/C compressor. 6. Disconnect the suction line from the A/C compressor and remove and discard the seal. 7. Install plugs in, or tape over the opened suction line fitting and the compressor port. Suction Line 8. Disengage the retainer that secures the suction line routing clip to the receiver/drier mounting bracket on the side of the right front strut tower in the engine compartment. 9. Remove the nut that secures the suction and liquid lines to the front A/C expansion valve. 10. Disconnect the suction and liquid lines from the front A/C expansion valve and remove and discard the O-ring seals. 11. Install plugs in, or tape over the opened suction and liquid line fittings and expansion valve ports. 12. Raise and support the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7534 Underbody Line Connections 13. Remove the tie strap and disconnect the suction line extension fitting from the underbody suction line and remove and discard the O-ring seal. 14. Install plugs in, or tape over the opened suction line fittings. 15. Lower the vehicle. INSTALLATION 1. Position the suction line into the engine compartment. 2. Remove the tape or plugs from the suction and liquid line fittings and expansion valve ports. 3. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the suction and liquid line fittings. 4. Connect the suction and liquid lines to the front A/C expansion valve. 5. Install the nut that secures the suction and liquid lines to the front A/C expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.). 6. Engage the retainer that secures the suction line routing clip to the receiver/drier mounting bracket on the side of the right front strut tower in the engine compartment. 7. Remove the tape or plugs from the A/C compressor port and the suction line fitting. 8. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the suction line fitting. 9. Connect the suction line to the A/C compressor. 10. Install the nut that secures the suction line to the A/C compressor. Tighten the nut to 23 N.m (17 ft. lbs.). 11. Connect the drain tube to the wiper module drain on the right side of the engine compartment. 12. Install the air cleaner top cover and snorkel onto the air cleaner housing located on the right side of the engine compartment. 13. Reconnect the negative battery cable. 14. Raise and support the vehicle. 15. Remove the tape or plugs from the suction line extension fitting and the underbody suction line. 16. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the underbody suction line. 17. Connect the suction line extension fitting to the underbody suction line. Tighten the fitting to 23 N.m (17 ft. lbs.). 18. Install a new tie strap just forward of the connections between the underbody plumbing and the engine compartment plumbing for the rear heating-A/C system. 19. Lower the vehicle. 20. Evacuate the refrigerant system. 21. Charge the refrigerant system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7535 Hose/Line HVAC: Service and Repair Underbody Lines Underbody Heater Tubes REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Drain the engine cooling system. 2. Raise and support vehicle. Underbody Heater Tube Quick Connect Fittings 3. Disconnect the underbody heater tubes at the rear of the vehicle by releasing the insert in the underbody heater tube quick connect fittings and carefully pulling downward on the heater tube fittings. 4. Lower the underbody heater tubes and drain any residual coolant from the tubes into a suitable container. Underbody Connections Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7536 5. Using spring tension clamp pliers, compress and slide the clamps off of the rubber hoses at the front of the underbody heater tubes. CAUTION: DO NOT apply excessive pressure on heater tubes or connections when removing heater hoses. Excessive pressure may damage or deform the tubes, causing an engine coolant leak. 6. Disconnect the heater hoses by carefully twisting the hoses back and forth on the rear heater extension tubes, while gently pulling them away from the end of the tubes. 7. If necessary, carefully cut the hose ends and peel the hoses off of the tubes. NOTE: Replacement of the heater hoses will be required if the hose ends are cut for removal. 8. Remove the screws that secure the underbody line retaining straps to the vehicle underbody. 9. Remove the underbody heater tubes from the retaining straps. 10. Remove the underbody heater tubes from the vehicle. INSTALLATION 1. Position the underbody heater tubes onto the vehicle underbody. 2. Install the underbody heater tubes into the underbody line retaining straps. 3. Install the bolts that secure the retaining straps to the vehicle underbody. Tighten the screws securely. 4. Connect the rubber hoses at the front of the underbody heater tubes to the rear heater extension tubes. 5. Using spring tension clamp pliers, compress and slide the clamps that secure the heater hoses over the extension tubes. Release the clamp when it is correctly positioned over the tube. 6. Connect the rear underbody heater tube quick connections to the rear heater core extension tubes. 7. Lower the vehicle. 8. Refill the engine cooling system. Underbody Refrigerant Line REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Raise and support vehicle. 3. Disconnect the exhaust system from the exhaust hanger rubber isolators and position the exhaust system out of the way. Underbody A/C Line Front Connections - Typical 4. Disconnect the underbody refrigerant lines from the front liquid and suction line extension tubes and remove and discard the O-ring seals. 5. Install plugs in, or tape over the opened refrigerant line fittings. 6. Remove the screws that secure the underbody line retaining straps to the vehicle underbody. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7537 7. Remove the underbody refrigerant lines from the retaining straps. Underbody A/C Line Rear Connections - With New Seating Element Underbody A/C Line Rear Connections - Without New Seating Element 8. Remove the bolt or nut (depending on application) that secures the underbody refrigerant lines to the rear evaporator extension line tapping plate, located behind the right rear wheel housing. 9. Disconnect the underbody refrigerant lines from the rear evaporator extension line tapping plate and remove and discard the O-ring seals. 10. Install plugs in, or tape over the opened underbody refrigerant line fittings and the rear evaporator extension line ports. 11. Remove the underbody refrigerant lines from the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Discharge Line > Page 7538 Underbody A/C Line Sealing Plate - Typical 12. If required, place the underbody refrigerant lines on a workbench, remove the nylon wedges that secure the underbody refrigerant lines to the underbody refrigerant line sealing plate and remove the lines from the sealing plate. INSTALLATION 1. If removed, install the underbody refrigerant lines into the underbody refrigerant line sealing plate and install the nylon wedges that secure the refrigerant lines to the sealing plate. 2. Position the underbody refrigerant lines onto the vehicle underbody. 3. Install the underbody refrigerant lines into the underbody line retaining straps. 4. Install the bolts that secure the retaining straps to the vehicle underbody. Tighten the screws securely. 5. Remove the tape or plugs from the rear underbody refrigerant line fittings and the rear evaporator extension line ports. 6. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the underbody refrigerant line fittings. 7. Connect the underbody refrigerant lines to the rear evaporator extension line tapping plate. 8. Install the bolt or nut (depending on application) that secures the underbody refrigerant line sealing plate to the rear evaporator extension line tapping plate. Tighten the bolt or nut to 23 N.m (17 ft. lbs.). 9. Remove the tape or plugs from the front liquid and suction line extension tubes and the underbody refrigerant line fittings. 10. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the underbody refrigerant line fittings. 11. Connect the underbody refrigerant line fittings to the front liquid and suction line extension tubes. Tighten the fittings to 23 N.m (17 ft. lbs.). 12. Position the exhaust system and install it to the exhaust hanger rubber isolators. 13. Lower the vehicle. 14. Evacuate the refrigerant system. 15. Charge the refrigerant system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations > Page 7542 Housing Assembly HVAC: Description and Operation NOTE: LHD model shown in illustration. RHD model similar. HVAC Housing Assembly All models are equipped with a common HVAC housing assembly that combines A/C and heating capabilities into a single unit mounted within the passenger compartment. The HVAC housing assembly consists of three separate housings: - HVAC housing - The HVAC housing mounted to the dash panel behind the instrument panel and contains the A/C evaporator and the blower motor resistor or power model (depending on application) and the particulate air filter (if equipped). The HVAC housing consists of a upper and a lower housing that are attached together and has mounting provisions for the air inlet housing, blower motor, air distribution housing and the HVAC wire harness. - Air inlet housing - The air inlet housing mounted to the right end of the HVAC housing and contains the recirculation-air door and actuator. - Air distribution housing - The air distribution housing is mounted to the rear of the HVAC housing and contains the heater core, blend-air doors and actuators, mode-air doors and actuator and door linkage. The heating-A/C system is a blend-air type system The blend-air doors control the amount of conditioned air that is allowed to flow through, or around, the heater core. The dual zone heating A/C system uses two blend door actuators. The A/C system is designed for the use of a non CFC, R-134a refrigerant and uses an A/C evaporator to cool and dehumidify the incoming air prior to blending it with the heated air. A temperature control determines the discharge air temperature by operating the blend door actuators, which moves the blend-air doors. This allows an almost immediate control of the output air temperature of the system. The mode door actuator operates the mode-air doors which direct the flow of the conditioned air out the various air outlets, depending on the mode selected. The recirculation door actuator operates the recirculation-air door which closes off the fresh air intake and recirculates the air already inside the vehicle. The electric door actuators are connected to the vehicle electrical system by the HVAC wire harness. The blower motor controls the velocity of air flowing through the HVAC housing assembly by spinning the blower wheel within the HVAC housing at the selected speed by use of the blower motor resistor or power model, depending on application. The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors. The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door. The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement Housing Assembly HVAC: Removal and Replacement Front Air Distribution Housing Removal and Installation REMOVAL WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. - REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: - The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors. - LHD model shown in illustrations. RHD model similar. 1. Remove the HVAC housing from the vehicle and place it on a workbench. Actuators 2. Disconnect the HVAC wire harness connectors from the mode door actuator and the blend door actuator(s) located on the driver side of the air distribution housing and position the HVAC wire harness out of the way. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7545 Heater Core Tubes 3. Remove the foam seal from the heater core tubes and the flange located at the front of the HVAC housing. If the seal is deformed or damaged, it must be replaced. 4. Remove the plastic retaining strap that secures the heater core tubes to the front of the HVAC housing. NOTE: Take the proper precautions to protect against spilled engine coolant. Have absorbent toweling readily available to clean up any spills. 5. Remove the bolt that secures the heater core tube sealing plate to the heater core. 6. Disconnect the heater core tubes from the heater core and remove and discard the O-ring seals. 7. Install plugs in, or tape over the opened heater core ports. Retainers - Air Distribution Housing 8. Remove the four screws that secure the air distribution housing to the rear of the HVAC housing. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7546 9. Tilt the top of the air distribution housing rearward to disconnect the distribution housing from the two tab-and-slot type retainers located at the bottom of the housing and remove the distribution housing. 10. If required, disassemble the air distribution housing. INSTALLATION NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors. 1. Install the air distribution housing onto the rear of the HVAC housing by inserting the two tabs on the bottom of the distribution housing into the slots located on the bottom of the HVAC housing and tipping the distribution housing forward until it is properly aligned with the HVAC housing. 2. Install the four screws that secure the air distribution housing to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.). 3. Remove the tape or plugs from the heater core ports. 4. Lubricate new rubber O-ring seals with clean engine coolant and install them onto the heater core tube fittings. Use only the specified O-ring as they are made of a special material for the engine cooling system. 5. Position both heater core tubes and the sealing plate simultaneously onto the heater core. NOTE: The heater core tubes each have a slot that must be indexed to a location tab within each of the heater core ports. Adjust the position of the tubes as required so that the sealing plate fits flush against the heater core supply and return ports, which indicates that the tubes are properly indexed. 6. Index both heater core tubes to the heater core ports. 7. Install the bolt that secures the heater core tube sealing plate to the heater core. Tighten the bolt to 3 N.m (27 in. lbs.). 8. Install the plastic retaining clamp that secures the heater core tubes to the front of the HVAC housing. 9. Install the foam seal onto the heater core tubes and the flange located at the front of the HVAC housing. 10. Position the HVAC wire harness onto the air distribution housing. 11. Connect the HVAC wire harness connectors to the mode door actuator and the blend door actuator(s) located on the driver side of the air distribution housing. 12. Install the HVAC housing assembly. Front Air Inlet Housing Removal and Installation REMOVAL WARNING: - REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: - The air inlet housing must be removed from HVAC housing for service of the recirculation-air door. - LHD model shown in illustrations. RHD model similar. 1. Remove the HVAC housing assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7547 Lower Air Inlet Housing 2. Remove the recirculation door actuator. 3. Remove the recirculation door actuator wire lead from the routing clip located on the lower air inlet housing and position the wire lead aside. 4. Disconnect the blower motor wire lead connector from the blower motor resistor or power module, depending on application. 5. Remove the one screw (from the top) that secures the lower air inlet housing to the upper air inlet housing. 6. Remove the four screws (from the bottom) that secure the lower air inlet housing to the upper air inlet housing and remove the lower HVAC housing. Blower Motor Wire Lead Grommet 7. Push the rubber blower motor wire lead grommet through the opening in the lower air inlet housing. 8. Feed the blower motor wire lead through the opening in the lower air inlet housing and remove the lower air inlet housing from the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7548 Upper Air Inlet Housing 9. Carefully cut the foam seal along the parting line of the upper air inlet housing. If the seal is deformed or damaged, it must be replaced. 10. Remove the three screws that secure the upper air inlet housing to HVAC housing. 11. Remove the upper air inlet housing and recirculation-air door from the HVAC housing. 12. If required, remove the screw that secures the recirculation-air door to the upper air inlet housing and remove the air door. INSTALLATION NOTE: The air inlet housing must be removed from HVAC housing for service of the recirculation-air door. 1. If removed, install the recirculation-air door into the upper air inlet housing and install the retaining screw. Tighten the screw to 2 N.m (17 in. lbs.). 2. Position the air inlet housing and recirculation-air door onto the HVAC housing. CAUTION: Make sure that the recirculation-air door pivot shaft is properly seated in the pivot seats. 3. Install the three screws that secure the upper air inlet housing to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.). 4. Inspect the foam seal along the parting line. If the seal is deformed or damaged, it must be replaced. 5. Feed the blower motor wire lead through the opening in the lower air inlet housing and seat the rubber grommet into the lower air inlet housing. 6. Position the recirculation-air door pivot into the lower air inlet housing. 7. Install the four screws (from the bottom) that secure the lower air inlet housing to the upper air inlet housing and the lower HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.). 8. Install the one screw (from the top) that secures the lower air inlet housing to the upper air inlet housing. Tighten the screws to 2 N.m (17 in. lbs.). 9. Connect the blower motor wire lead connector to the blower motor resistor or power module, depending on application. 10. Install the recirculation door actuator wire lead into the routing clip located on the lower air inlet housing. 11. Install the recirculation door actuator. 12. Install the HVAC housing assembly. Front HVAC Housing Removal and Installation REMOVAL WARNING: - REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7549 AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. NOTE: - The HVAC housing must be removed from the vehicle and disassembled for service of the air inlet housing, air distribution housing and the A/C evaporator. - Take the proper precautions to protect the front face of the instrument panel from cosmetic damage while performing this procedure. - LHD model shown in illustrations. RHD model similar. 1. Recover the refrigerant from the refrigerant system. 2. Drain the engine cooling system. 3. Disconnect and isolate the negative battery cable. 4. Disconnect the liquid and suction lines from the A/C expansion valve. 5. Disconnect the heater hoses from the heater core. HVAC Housing-Engine Compartment 6. Remove the three nuts that secure the HVAC housing to the engine compartment side of the dash panel. 7. Remove the instrument panel from the passenger compartment. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7550 HVAC Housing-Passenger Compartment 8. Remove the nut and bolt that secure the HVAC housing to the passenger compartment side of the dash panel. 9. Pull the HVAC housing rearward to clear the dash panel and remove the HVAC housing from the passenger compartment. 10. If required, disassemble the HVAC housing. INSTALLATION NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the air inlet housing, air distribution housing and the A/C evaporator. 1. Position the HVAC housing against the dash panel in the passenger compartment with the three mounting studs located in their proper holes. Make sure that the condensate drain tube protrudes through its opening. 2. Loosely install the nut and bolt that secures the HVAC housing to the passenger compartment side of the dash panel. 3. Install the three nuts that secure the HVAC housing to the engine compartment side of the dash panel. Tighten the nuts to 7 N.m (62 in. lbs.). 4. Tighten the nut and bolt that secures the HVAC housing to the passenger compartment side of the dash panel to 3 N.m (26 in. lbs.). 5. Install the instrument panel. 6. Connect the heater hoses to the heater core. 7. Connect the suction and liquid lines to the A/C expansion valve. 8. Reconnect the negative battery cable. 9. If the heater core is being replaced, flush the cooling system. 10. Refill the engine cooling system. 11. Evacuate the refrigerant system. 12. Charge the refrigerant system. 13. Calibrate the A/C-heater control. Rear HVAC Housing Removal and Installation REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The rear HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator and the mode/blend-air door. 1. Recover the refrigerant from the refrigerant system. 2. Drain the engine cooling system. 3. Disconnect and isolate the negative battery cable. 4. Raise and support the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7551 Underbody A/C Line Rear Connections - With New Seating Element (NSE) Underbody A/C Line Rear Connections - Without New Seating Element (NSE) 5. Remove the nut that secures the underbody refrigerant line sealing plate to the rear evaporator extension line tapping plate that extends through the rear floor panel behind the right rear wheel housing. 6. Disconnect the underbody refrigerant lines from the rear evaporator extension line tapping plate and remove and discard the O-ring seals. 7. Install plugs in, or tape over the opened underbody refrigerant line fittings and the evaporator extension line sealing plate ports. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7552 Rear HVAC Housing Mounting Studs - Typical 8. Remove the nuts from the mounting studs that secure the rear HVAC housing to the rear floor panel behind the right rear wheel housing. 9. Lower the vehicle. 10. Remove the trim panels from the inner right quarter panel and the right D-pillar. 11. Remove the rear distribution duct from the rear HVAC housing and the rear headliner duct. 12. Disconnect the body wire harness connector for the rear HVAC housing from the rear HVAC wire harness connector located near the A/C expansion valve. 13. Remove the two screws that secure the top of the quarter trim panel attaching bracket to the inner quarter panel. 14. Remove the two screws that secure the bottom of the quarter trim panel attaching bracket to the rear HVAC housing. 15. Remove the rear floor heat duct from the inner right quarter panel. NOTE: Use absorbent toweling to clean up any engine coolant spills. 16. Disconnect the heater hoses at the rear heater core. 17. Install plugs in, or tape over the opened heater core fittings and both heater hoses. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7553 Rear HVAC Housing 18. Remove the screw that secures the back of the rear HVAC housing to the right D-pillar. 19. Remove the screw that secures the front of the rear HVAC housing to the inner right quarter panel. 20. Lift the rear HVAC housing up far enough for the lower mounting studs and the evaporator extension lines to clear the mounting holes in the rear floor panel and remove the housing. INSTALLATION NOTE: If the rear heater core or the rear HVAC housing have been removed from the vehicle for service, the rear heater core should be pre-filled with the proper engine coolant mixture prior to reconnecting the heater hoses to the heater core hose fittings. 1. Position the rear HVAC housing into the vehicle with the evaporator extension line sealing plate inserted into the opening in the rear floor panel behind the right rear wheel house. 2. Align the rear HVAC housing lower mounting studs with the holes in the rear floor panel and lower the rear HVAC housing to the floor. 3. Install the screw that secures the front of the rear HVAC housing to the inner right quarter panel. Tighten the screw to 11 N.m (97 in. lbs.). 4. Install the screw that secures the back of the rear HVAC housing to the right D-pillar. Tighten the screw to 11 N.m (97 in. lbs.). 5. Remove the plugs or tape from both heater core fittings and both heater hoses. 6. Pre-fill the rear heater core. 7. Connect the heater hoses to the rear heater core. 8. Install the rear floor heat duct onto the inner right quarter panel. 9. Install the two screws that secure the bottom of the quarter trim panel attaching bracket to the rear HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.). 10. Install and tighten the two screws that secure the top of the quarter trim panel attaching bracket to the inner quarter panel. 11. Connect the wire harness connector to the rear HVAC wire harness connector. 12. Install the rear distribution duct onto the rear HVAC housing and the rear headliner duct. 13. Install the trim panels onto the right inner quarter panel and right D-pillar. 14. Raise and support the vehicle. 15. Install the three nuts that secure the rear HVAC housing mounting studs to the rear floor panel behind the right rear wheel housing. Tighten the nuts to 9 N.m (80 in. lbs.). 16. Remove the tape or plugs from the underbody refrigerant line fittings and both ports in the rear evaporator extension line sealing plate. 17. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the underbody refrigerant line fittings. 18. Connect the underbody refrigerant line sealing plate to the evaporator extension line tapping plate. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7554 19. Install the nut that secures the underbody refrigerant line sealing plate to the evaporator extension line tapping plate. Tighten the nut to 23 N.m (17 ft. lbs.). 20. Lower the vehicle. 21. Reconnect the negative battery cable. 22. Refill the engine cooling system. 23. Evacuate the refrigerant system. 24. Charge the refrigerant system. 25. Calibrate the A/C-heater control. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7555 Housing Assembly HVAC: Overhaul Air Distribution Housing DISASSEMBLY NOTE: - The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors. - LHD model shown in illustrations. RHD model similar. 1. Remove the air distribution housing from the HVAC housing and place it on a workbench. Actuators And Heater Core 2. Remove the two screws that secure the heater core to the driver side of the air distribution housing and carefully remove the heater core. 3. Remove the screws that secure the mode door actuator and the blend door actuator(s) to the driver side of the air distribution housing and remove the actuators. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7556 Air Door Linkage 4. Remove the defrost door linkage arm, instrument panel door linkage arm, mode door cam, floor door gear, driver side blend door gear (if equipped) and the passenger side blend door stop from the driver side of the air distribution housing. Front Floor Distribution Duct 5. Remove the six screws that secure the floor distribution ducts to the air distribution housing and remove the ducts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7557 Air Distribution Housing Screws 6. Remove the screw from the center of the driver side of the air distribution housing. 7. Carefully cut the foam seal along the parting line of the two halves of the air distribution housing. If the seal is deformed or damaged, it must be replaced. 8. Remove the seven screws that secure the two halves of the air distribution housing together and carefully separate the housing. Dual Zone Driver Side Blend-Air Door 9. If equipped with dual zone heating -A/C system, push down on the retaining tab of the driver side blend door gear and carefully pull the gear out of the blend door pivot shaft. NOTE: If the seal on the air door is deformed or damaged, the air door must be replaced. 10. Remove the blend-air door from the driver side of the air distribution housing. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7558 Air Doors And Partition - Driver Side 11. Remove the screw that secures the driver side air vane to the passenger side of the air distribution housing and remove the vane. NOTE: If the seal on any air door is deformed or damaged, the air door must be replaced. 12. Remove the air doors and the partition from the air distribution housing. Air Doors And Vane - Passenger Side 13. Remove the screw that secures the passenger side air vane to the passenger side of the air distribution housing and remove the vane. NOTE: If the seal on any air door is deformed or damaged, the air door must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7559 14. Remove the air doors from the passenger side of the air distribution housing. ASSEMBLY NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors. 1. Install the air doors into the passenger side of the air distribution housing as required. Align the air doors with the pivot shaft holes in the housing. 2. Install the air vane and retaining screw to the passenger side of the air distribution housing. Tighten the screw to 2 N.m (17 in. lbs.). 3. Align the air door pivot shafts with the pivot holes in the center partition and install the partition onto the passenger side of the air distribution housing. 4. Install the driver side air vane and retaining screw to the center partition. Tighten the screw to 2 N.m (17 in. lbs.). 5. Install the blend-air door to the driver side of the air distribution housing. Align the air door with the pivot shaft hole in the housing. 6. If equipped with dual zone heating-A/C system, align and install the blend door gear into the pivot shaft of the driver side blend-air door. Make sure that the retaining tab on the door gear is securely engaged to the pivot shaft. 7. Align the air door pivot shafts to each other and carefully install the driver side half of the air distribution housing to the passenger side half of the housing. 8. Install the seven screws that secure the two halves of the air distribution housing together. Tighten the screws to 2 N.m (17 in. lbs.). 9. Inspect the foam seal, especially at the parting line. If the seal is deformed or damaged, it must be replaced. 10. Install the screw to the center of the driver side air distribution housing. Tighten the screw to 2 N.m (17 in. lbs.). 11. Position the floor distribution ducts onto the air distribution housing. 12. Install the six screws that secure the floor distribution ducts to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.). NOTE: Align the guide pin on the linkage arms with the guides on the mode door cam during installation of the floor door gear and linkage arms. 13. Install the passenger side blend door stop, driver side blend door gear (if equipped), floor door gear, mode door cam, instrument panel door linkage arm and the defrost door linkage arm onto the driver side of the air distribution housing. 14. Position the mode door and blend door actuators onto the driver side of the air distribution housing. If necessary, rotate the actuators slightly to align the splines on the actuator output shaft with those in the air door linkage. 15. Install the two screws that secure each actuator to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.). 16. Carefully install the heater core into the driver side of the air distribution housing. 17. Install the two screws that secure the heater core to the air distribution housing. Tighten the screw to 2 N.m (17 in. lbs.). 18. Install the air distribution housing onto the HVAC housing. HVAC Housing DISASSEMBLY NOTE: - The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator. - LHD model shown in illustrations. RHD model similar. 1. Remove the HVAC housing from the vehicle and place it on a workbench. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7560 HVAC Housing Assembly 2. Remove the air distribution housing from the HVAC housing. 3. Remove the air inlet housing from the HVAC housing. 4. Remove the A/C expansion valve from the A/C evaporator. HVAC Housing 5. Disconnect the HVAC wiring harness from the blower motor resistor or power module (depending on application). 6. Disengage the HVAC wire harness from the routing clips on the HVAC housing and remove the wire harness from the housing. 7. If required, remove three screws that secure the blower motor to the HVAC housing and remove the blower motor. 8. If required, remove two screws that secure the blower motor resistor or power module (depending on application) to the HVAC housing and remove the resistor or module. 9. If required, remove two screws that secure the support bracket to the HVAC housing and remove the bracket. 10. Remove the thirteen screws that secure the upper HVAC housing half to the lower half of the HVAC housing. 11. Separate the two halves of the HVAC housing. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7561 12. Carefully lift the A/C evaporator and insulator out of the lower half of the HVAC housing. ASSEMBLY 1. Install the A/C evaporator into the lower half of the HVAC housing. Make sure that the evaporator drain within the HVAC housing is clean and unrestricted and that the insulator around the A/C evaporator is properly installed. 2. Install the upper half of the HVAC housing onto the lower half of the HVAC housing. 3. Install the thirteen screws that secure the two halves of the HVAC housing together. Tighten the screws to 2 N.m (17 in. lbs.). 4. If removed, install the support bracket and the two retaining screws. Tighten the screws to 2 N.m (17 in. lbs.). 5. If removed, install the blower motor resistor or power module (depending on application) and the two retaining screws. Tighten the screws to 2 N.m (17 in lbs.). 6. If removed, install the blower motor and the three retaining screws. Tighten the screws to 2 N.m (17 in. lbs.). 7. Install the HVAC wiring harness. Make sure the harness is routed through all wiring retainers. 8. Engage the HVAC wire harness into the routing clips on the HVAC housing. 9. Connect the HVAC wire harness connector to the blower motor resistor or power module (depending on application). 10. Install the A/C expansion valve. 11. Install the air inlet housing onto the HVAC housing. 12. Install the air distribution housing onto the HVAC housing. 13. Install the HVAC housing into the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation Receiver Dryer: Description and Operation The receiver/drier stores unnecessary refrigerant, filters the refrigerant, helps remove moisture from the refrigerant and retains any refrigerant vapor that may leave the A/C condenser until it becomes a liquid. The receiver/drier is installed on the high-side of the A/C system between the front and rear sections of the A/C liquid line. The receiver/drier performs a filtering action to prevent foreign material in the refrigerant from contaminating the A/C expansion valve. Refrigerant enters the receiver/drier as a high-pressure, low temperature liquid. Desiccant inside the receiver/drier absorbs any moisture which may have entered and become trapped within the refrigerant system. In addition, during periods of high demand operation of the A/C system, the receiver/drier acts as a reservoir to store surplus refrigerant. The receiver/drier cannot be repaired. If the receiver/drier is faulty or damaged, or if the refrigerant system has been contaminated or left open to the atmosphere for an indeterminable period or if the A/C compressor has failed, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 7565 Receiver Dryer: Service and Repair REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. 1. Recover the refrigerant from the refrigerant system. 2. Remove the air cleaner housing from the right side of the engine compartment. Receiver/Drier - LHD Shown, RHD Typical 3. Remove the bolts that secure both liquid line fittings to the receiver/drier. 4. Disconnect both liquid line fittings from the receiver/drier and remove and discard the O-ring seals. 5. Install plugs in, or tape over the opened liquid line fittings and the receiver/drier ports. 6. Remove the two nuts that secure the receiver/ drier mounting bracket to the weld studs on the side of the right front strut tower and remove the receiver/drier. INSTALLATION NOTE: If the receiver/drier is being replaced, add 25 milliliters (0.8 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 1. Position the receiver/drier and mounting bracket onto the weld studs on the side of the right front strut tower. 2. Install the two nuts that secure the receiver/ drier mounting bracket to the studs. Tighten the nuts to 10 N.m (89 in. lbs.). 3. Remove the tape or plugs from the two liquid line fittings and the receiver/drier ports. 4. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the two liquid line fittings. 5. Connect the liquid line fittings to the receiver/ drier. 6. Install the bolt that secures each liquid line fitting to the receiver/drier. Tighten the bolts to 11 N.m (97 in. lbs.). 7. Install the air cleaner housing. 8. Evacuate the refrigerant system. 9. Charge the refrigerant system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Information not supplied by the manufacturer. Refer to the sticker under the hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 7570 Refrigerant: Fluid Type Specifications Refrigerant Type .................................................................................................................................. ...................................................................... R-134a Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 7571 Refrigerant: Description and Operation The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure, refrigerant oil sludge or poor A/C system performance. In addition, the polyalkylene glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a refrigerant system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is equipped with R-134a refrigerant. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Front A/C Total System Fill .................................................................................................................................. ................................................. 6.1 fl. oz (180 ml) Receiver/Drier ....................................................... .................................................................................................................................. 0.8 fl. oz (25 ml) A/C Condenser .................................................................................................................................... .................................................... 1.7 fl. oz (50 ml) Front Evaporator .................................................. ................................................................................................................................... 1.7 fl. oz (50 ml) A/C Compressor ......................................................................................................................... Drain and measure the oil from the old compressor. Front and Rear A/C Total System Fill .................................................................................................................................. ................................................. 7.8 fl. oz (230 ml) Receiver/Drier ....................................................... .................................................................................................................................. 0.8 fl. oz (25 ml) A/C Condenser .................................................................................................................................... .................................................... 1.7 fl. oz (50 ml) Front Evaporator .................................................. ................................................................................................................................... 1.7 fl. oz (50 ml) Rear Evap. (including underbody lines) .................................................................................................................................................. 1.7 fl. oz (50 ml) A/C Compressor ......................................................................................................................... Drain and measure the oil from the old compressor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 7576 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil ..................................................................................................................................... ................................................................ ND-8 PAG Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 7577 Refrigerant Oil: Description and Operation The refrigerant oil used in R-134a refrigerant systems is a synthetic-based, polyalkylene glycol (PAG), wax-free lubricant. Mineral-based R-12 refrigerant oils are not compatible with PAG oils, and should never be introduced to an R-134a refrigerant system. There are different PAG oils available, and each contains a different additive package. The Denso 10S17 and 10S20 A/C compressors used in this vehicle are designed to use ND-8 PAG refrigerant oil. Use only this type of refrigerant oil the refrigerant system. After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system performance. PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page 7578 Refrigerant Oil: Service and Repair REFRIGERANT OIL LEVEL When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The receiver/drier, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: The oil used in the Denso 10S17 and 10S20 A/C compressors is ND-8 PAG R-134a refrigerant oil. Only refrigerant oil of the same type should be used to service the A/C system. Do not use any other refrigerant oil. The oil container should be kept tightly capped until it is ready for use and then tightly capped after use to prevent contamination from dirt and moisture. Refrigerant oil will quickly absorb any moisture it comes in contact with, therefore, special effort must be used to keep all R-134a system components moisture-free. Moisture in the refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the lubricant being removed during recovery. This amount of lubricant should be added back into the system. Refer to the reclaim/recycling equipment manufacturers instructions. It will not be necessary to check the oil level in the A/C compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant Oil Capacities Refrigerant oil must be added when a receiver/ drier, A/C evaporator or A/C condenser is replaced. See the Refrigerant Oil Capacities chart. When an A/C compressor is replaced, the refrigerant oil must be drained from the old compressor and measured. Drain all of the refrigerant oil from the new A/C compressor, then fill the new compressor with the same amount of refrigerant oil that was drained out of the old compressor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Diagrams A/C Pressure Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 7587 Blower Motor Relay: Diagrams 8w-10-3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 7588 8w-10-5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Page 7589 Front Blower Motor Relay Rear Blower Motor Relay Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay: Description and Operation Front Front Blower Motor Relay The blower motor relay for the front heating-A/C system is an International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns. The front blower motor relay is located in the integrated power module (IPM) in the engine compartment. The front blower motor relay is an electromechanical switch that uses a low current input from the front control module (FCM) to control the high current output to the blower motor resistor (manual temperature control) or the blower motor power module (automatic temperature control). The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the blower motor. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The blower motor relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the blower motor relay include: - The common feed terminal (30) receives a battery current input from the battery through a B(+) circuit at all times. - The coil ground terminal (85) receives a ground input through the front/rear blower motor relay control circuit only when the FCM electronically pulls the control circuit to ground. - The coil battery terminal (86) receives a battery current input from the battery through a B(+) circuit at all times. - The normally open terminal (87) provides a battery current output to the blower motor resistor (manual temperature control) or blower motor power module (automatic temperature control) through a fuse in the IPM on the fused front blower motor relay output circuit only when the blower motor relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the blower motor relay coil is de-energized. The blower motor relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard relay and for complete HVAC wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front > Page 7592 Blower Motor Relay: Description and Operation Rear Rear Blower Motor Relay The blower motor relay for the rear heating-A/C system is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns. The rear blower motor relay is located in the integrated power module (IPM) in the engine compartment. The rear blower motor relay is an electromechanical switch that uses a low current input from the front control module (FCM) to control the high current output to the rear blower motor resistor (manual temperature control) or rear blower motor power module (automatic temperature control). The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the rear blower motor. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear blower motor relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the rear blower motor relay include: - The common feed terminal (30) receives a battery current input from the battery through a B(+) circuit at all times. - The coil ground terminal (85) receives a ground input through the front/rear blower motor relay control circuit only when the FCM electronically pulls the control circuit to ground. - The coil battery terminal (86) receives a battery current input from the battery through a B(+) circuit at all times. - The normally open terminal (87) provides a battery current output to the blower motor resistor (manual temperature control) or blower motor power module (automatic temperature control) through a fuse in the IPM on the fused rear blower motor relay output circuit only when the rear blower motor relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the rear blower motor relay coil is de-energized. Refer to the appropriate wiring information for diagnosis and testing of the micro-relay and for complete HVAC wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair > Front Blower Motor Relay: Service and Repair Front REMOVAL 1. Disconnect and isolate the negative battery cable. Front Blower Motor Relay 2. Remove the cover from the integrated power module (IPM) located in the engine compartment. NOTE: Refer to the fuse and relay map on the IPM cover for front blower motor relay location. 3. Remove the front blower motor relay from the IPM. INSTALLATION NOTE: Refer to the fuse and relay map on the cover of the integrated power module (IPM) for front blower motor relay location. 1. Position the front blower motor relay to the proper receptacle in the IPM. 2. Align the front blower motor relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair > Front > Page 7595 Blower Motor Relay: Service and Repair Rear REMOVAL 1. Disconnect and isolate the negative battery cable. Rear Blower Motor Relay 2. Remove the cover from the integrated power module (IPM). NOTE: Refer to the fuse and relay map on the IPM cover for rear blower motor relay location. 3. Remove the rear blower motor relay from the IPM. INSTALLATION NOTE: Refer to the fuse and relay map on the cover of the integrated power module (IPM) for rear blower motor relay location. 1. Position the rear blower motor relay to the proper receptacle in the IPM. 2. Align the rear blower motor relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 7599 Compressor Clutch Relay: Diagrams 8w-10-3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 7600 8w-10-5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 7601 A/C Compressor Clutch Relay 2002-06 Mini Vans A/C Compressor Clutch 2003 Voyager, Caravan Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 7602 Compressor Clutch Relay: Description and Operation A/C Compressor Clutch Relay The A/C clutch relay is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns. The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The A/C clutch relay is located in the integrated power module (IPM) in the engine compartment. The ISO-standard A/C clutch micro-relay is an electromechanical switch that uses a low current input controlled by the powertrain control module (PCM) to control the high current output to the A/C clutch field coil. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the A/C clutch field coil. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The A/C clutch relay terminals are connected to the vehicle electrical system through a receptacle in the integrated power module (IPM). The inputs and outputs of the A/C compressor clutch relay include: - The common feed terminal (30) receives a battery current input from a fuse in the IPM through a fused B(+) circuit at all times. - The coil ground terminal (85) receives a ground input from the PCM through the compressor clutch relay control circuit only when the PCM electronically pulls the control circuit to ground. - The coil battery terminal (86) receives a battery current input from the PCM through a fused ignition switch output (run-start) circuit only when the ignition switch is in the On or Start positions. - The normally open terminal (87) provides a battery current output to the compressor clutch coil through the compressor clutch relay output circuit only when the compressor clutch relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the compressor clutch relay coil is de-energized. The A/C clutch relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard micro-relay and for complete HVAC wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 7603 Compressor Clutch Relay: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. A/C Compressor Clutch Relay 2. Remove the cover from the integrated power module (IPM) located in the engine compartment. NOTE: Refer to the fuse and relay map on the inside of the IPM cover for A/C compressor clutch relay location. 3. Remove the A/C compressor clutch relay from the IPM. INSTALLATION NOTE: Refer to the fuse and relay map on the inside of the integrated power module (IPM) cover for A/C compressor clutch relay location. 1. Position the A/C compressor clutch relay into the receptacle in the IPM. 2. Align the A/C compressor clutch relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams Control Module HVAC: Diagrams Front Blower Module C1 (ATC) Front Blower Module C2 (ATC) Rear Blower Motor Power Module C1 (3 Zone ATC) Rear Blower Motor Power Module C2 (3 Zone ATC) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Front Control Module HVAC: Description and Operation Front Front Blower Power Module A front blower motor power module is used on this model when it is equipped with the automatic temperature control (ATC) heating-A/C system. Models equipped with the manual temperature control (MTC) heating-A/C system use a blower motor resistor, instead of the blower motor power module. The front blower motor power module is mounted to the rear of the front HVAC housing, directly behind the glove box. The blower motor power module consists of a molded plastic mounting plate with two integral connector receptacles (1). Concealed behind the mounting plate is the power module electronic circuitry and a large finned heat sink (2). The front blower motor power module is accessed for service by removing the glove box. The front blower motor power module is connected to the vehicle electrical system through a dedicated lead and connector of the front HVAC wire harness. A second connector receptacle receives the wire harness connector from the front blower motor. The front blower motor power module allows the microprocessor-based automatic temperature control (ATC) A/Cheater control to calculate and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a pulse width modulated (PWM) circuit strategy. The PWM voltage is applied to a comparator circuit which compares the PWM signal voltage to the front blower motor feedback voltage. The resulting output drives the power module circuitry, which provides a linear output voltage to change or maintain the desired blower speed. The front blower motor power module is diagnosed using a DRBIII(R) scan tool. The front blower motor power module cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Front > Page 7609 Control Module HVAC: Description and Operation Rear Rear Blower Motor Power Module A rear blower motor power module is used on this model when it is equipped with the automatic temperature control (ATC) heating-A/C system.Models equipped with the manual temperature control (MTC) heating-A/C system use a blower motor resistor, instead of the blower motor power module. The rear blower motor power module is installed in the back of the rear HVAC housing, directly above the A/C expansion valve. The power module consists of a molded plastic mounting plate with two integral connector receptacles. Concealed behind the mounting plate is the power module electronic circuitry and a large finned heat sink. The rear blower motor power module is accessed for service by removing the right quarter and D-pillar trim panels. The rear blower motor power module is connected to the vehicle electrical system through a dedicated lead and connector of the rear HVAC wire harness. A second connector receptacle receives the wire harness connector from the rear blower motor. The rear blower motor power module allows the microprocessor-based automatic temperature control (ATC) A/Cheater control to calculate and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a pulse width modulated (PWM) circuit strategy. The PWM voltage is applied to a comparator circuit which compares the PWM signal voltage to the rear blower motor feedback voltage. The resulting output drives the power module circuitry, which adjusts the voltage output received from the rear blower motor relay to change or maintain the desired blower speed. The rear blower motor power module is diagnosed using a DRBIII(R) scan tool. The rear blower motor power module cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module Control Module HVAC: Service and Repair Front Blower Motor Power Module REMOVAL WARNING: - ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE NEGATIVE BATTERY (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIR-BAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. - THE HEAT SINK FOR THE BLOWER MOTOR POWER MODULE MAY GET VERY HOT DURING NORMAL OPERATION. IF THE BLOWER MOTOR WAS TURNED ON PRIOR TO SERVICING THE BLOWER MOTOR POWER MODULE, WAIT FIVE MINUTES TO ALLOW THE HEAT SINK TO COOL BEFORE PERFORMING DIAGNOSIS OR SERVICE. FAILURE TO TAKE THIS PRECAUTION CAN RESULT IN POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the negative battery cable. 2. Remove the glove box from the instrument panel. 3. Disconnect the two wire harness connectors from the front blower motor power module. Front Blower Motor Power Module 4. Remove the two screws that secure the front blower motor power module to the front HVAC housing and remove the power module. INSTALLATION 1. Position the front blower motor power module into the front HVAC housing. 2. Install the two screws that secure the front blower motor power module to the front HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.). 3. Connect the two wire connectors to the front blower motor power module. 4. Install the glove box. 5. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module > Page 7612 Control Module HVAC: Service and Repair Rear Blower Motor Power Module REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the right quarter trim panel and right D-pillar trim panel from the quarter inner panel. Rear Blower Motor Power Module 3. Disconnect the rear HVAC wire harness connector from the rear blower motor power module. 4. Disconnect the rear blower motor wire harness connector from the rear blower motor power module. 5. Remove the two screws that secure the rear blower motor power module to the rear HVAC housing and remove the power module. INSTALLATION 1. Position the rear blower motor power module into the rear HVAC housing. 2. Install the two screws that secure the rear blower motor power module to the rear HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.). 3. Connect the rear blower motor wire harness to the rear blower motor power module. 4. Connect the rear HVAC wire harness connector to the rear blower motor power module. 5. Install the right quarter trim panel and right D-pillar trim panel onto the quarter inner panel. 6. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7617 Ambient Temperature Sensor / Switch HVAC: Diagrams Ambient Temperature Sensor ATC Remote Sensor (ATC) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Infrared Temperature Sensor Ambient Temperature Sensor / Switch HVAC: Description and Operation Infrared Temperature Sensor Infrared Temperature Sensor - RS Shown, RG Typical The infrared temperature sensor consists of two infrared transducers that are concealed behind a clear lens located near the top of the instrument panel center bezel. These sensors are used only on models equipped with the optional automatic temperature control (ATC) heating-A/C system. A molded plastic connector receptacle on the bottom of the panel outlet unit is concealed behind the center bezel. A short, dedicated jumper wire harness routed behind the center bezel connects the sensors directly to the ATC A/C-heater control module near the bottom of the center bezel. The infrared temperature sensor is integral to the center bezel panel outlet. The infrared sensor detects thermal radiation emitted by the driver and front passenger seat occupants and their surroundings and converts its data into a linear pulse width modulated (PWM) output signal which is read by the automatic temperature control (ATC) A/C-heater control. The ATC A/C-heater control uses the infrared sensor data as one of the inputs necessary to automatically control the interior cabin temperature level. By using thermal radiation (surface temperature) measurement, rather than an air temperature measurement, the ATC heating-A/C system is able to adjust itself to the comfort level as perceived by the occupant. This allows the ATC system to compensate for other ambient conditions affecting comfort levels, such as solar heat gain or evaporative heat loss. The ATC system logic responds to the infrared sensor message by calculating and adjusting the air flow temperature and air flow rate needed to properly obtain and maintain the selected comfort level temperature of the occupants. The A/C-heater control continually monitors the infrared sensor circuits, and will store diagnostic trouble codes (DTCs) for any problem it detects. The infrared sensor is diagnosed using a DRBIII(R) scan tool. The infrared sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Infrared Temperature Sensor > Page 7620 Ambient Temperature Sensor / Switch HVAC: Description and Operation Ambient Temp Sensor Ambient air temperature is monitored by the overhead console through ambient temperature messages received from the Powertrain Control Module (PCM) over the Programmable Communications Interface (PCI) data bus circuit. The PCM receives a hard wired input from the ambient temperature sensor. The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the headlamp mounting module grille opening, behind the radiator grille and in front of the engine compartment. The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent by the Powertrain Control Module (PCM). The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the PCM. Based upon the resistance in the sensor, the PCM senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. The PCM then sends the proper ambient temperature messages to the Electronic Vehicle Information Center (EVIC)/Compass Mini-Trip Computer (CMTC) over the Programmable Communication Interface (PCI) data bus. The thermometer function is supported by the ambient temperature sensor, a wiring circuit, the PCM, the PCI data bus, and the Electronics module. If any portion of the ambient temperature sensor circuit fails, the PCM will self-diagnose the circuit. The ambient temperature sensor circuit can also be diagnosed manually. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect to determine the cause. For complete circuit diagrams, refer to the appropriate wiring information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Testing and Inspection > Ambient Temperature Sensor Ambient Temperature Sensor / Switch HVAC: Testing and Inspection Ambient Temperature Sensor 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector. 2. Measure the resistance of the ambient temperature sensor. At room temperature (approx. 68° F), the sensor resistance should be between 10-13 Kilohms. The sensor resistance should be between these two values at 68° F. If the resistance is out of range replace the ambient temperature sensor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Testing and Inspection > Ambient Temperature Sensor > Page 7623 Ambient Temperature Sensor / Switch HVAC: Testing and Inspection Ambient Temperature Sensor Circuit 1. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect the ambient temperature sensor wire harness connector and the Powertrain Control Module (PCM) wire harness connector. 2. Connect a jumper wire between the two terminals in the body half of the ambient temperature sensor wire harness connector. 3. Check for continuity between the sensor return circuit and the ambient temperature sensor signal circuit cavities of the PCM wire harness connector. There should be continuity. If OK, go to Step 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 4. Remove the jumper wire from the body half of the ambient temperature sensor wire harness connector. Check for continuity between the sensor return circuit cavity of the PCM wire harness connector and a good ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted sensor return circuit as required. 5. Check for continuity between the ambient temperature sensor signal circuit cavity of the PCM wire harness connector and a good ground. There should be no continuity. If OK, Driver/Vehicle Information Display to determine the cause. If not OK, repair the shorted ambient temperature sensor signal circuit as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Testing and Inspection > Page 7624 Ambient Temperature Sensor / Switch HVAC: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. From behind the front bumper fascia, remove the screw holding the sensor to the radiator closure panel. 3. Disconnect the sensor electrical connector. 4. Remove the sensor from vehicle. INSTALLATION 1. Position the sensor in the vehicle and connect the sensor electrical connector. 2. From behind the front bumper fascia, install the sensor mounting screw. 3. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations Headliner Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Page 7628 Blower Motor Switch: Diagrams Rear Blower Front Control Switch (3 Zone MTC) Rear Blower Rear Control Switch C1 (3 Zone MTC) Rear Blower Rear Control Switch C2 (3 Zone MTC) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7632 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7633 Evaporator Temperature Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7634 Evaporator Temperature Sensor / Switch: Description and Operation Evaporator Temperature Sensor - Typical The evaporator temperature sensor used for the manual and automatic temperature control systems on RS models is installed on the top of the HVAC housing behind the instrument panel and measures the air temperature downstream of the evaporator. The sensor is an electrical thermistor in a plastic housing that is inserted into the HVAC housing. Two terminals within the molded plastic connector receptacle on the sensor connect it to the vehicle electrical system through a take out and connector of the HVAC wire harness. Evaporator Temperature Sensor - RG Models The evaporator temperature sensor used for the manual and automatic temperature control systems on RG models is installed on the top of the expansion valve in the right rear corner of the engine compartment and measures the temperature of the evaporator coils. The sensor has a small probe that is Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations > Page 7635 inserted in a small well in the body of the expansion valve that is filled with a special silicone-based thermal grease. A small molded plastic push-in retainer secures the sensor to a threaded hole in the top surface of the expansion valve. Two terminals within a molded plastic connector receptacle on the sensor connect it to the vehicle electrical system through a take out and connector of the HVAC wire harness. The evaporator temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The evaporator temperature sensor monitors the temperature of the conditioned air once it passes through the A/C evaporator. The evaporator temperature sensor will change its internal resistance in response to the air temperatures it monitors and is connected to the A/C-heater control through sensor ground and signal circuits. As the conditioned air temperature increases, the resistance of the evaporator temperature sensor decreases and the voltage monitored by the A/C-heater control decreases. The external location of the evaporator temperature sensor allows the sensor to be removed or installed without disturbing the refrigerant in the A/C system. The A/C-heater control uses this monitored voltage reading as an indication of the evaporator temperature. The A/C-heater control is programmed to respond to this input by sending electronic messages to the powertrain control module (PCM) over the controller area network (CAN) data bus. The PCM then cycles the A/C compressor clutch as necessary to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The evaporator temperature sensor is diagnosed using the DRBIII(R) scan tool. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > RG Models Evaporator Temperature Sensor / Switch: Service and Repair RG Models REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the air cleaner housing from the right side of the engine compartment. 3. Remove the windshield wiper assembly from the vehicle. 4. If equipped with rear A/C, disconnect the liquid and suction lines from the A/C expansion valve. Evaporator Temperature Sensor (RG Models) - Rear A/C Shown 5. Remove the retainer that secures the evaporator temperature sensor to the A/C expansion valve. NOTE: To disconnect the wire harness connector from the evaporator temperature sensor, first push the red retaining ring toward the connector to release the lock, then disconnect the connector from the sensor. 6. Remove the evaporator temperature sensor from the A/C expansion valve and disconnect the wire harness connector. INSTALLATION NOTE: Any grease removed with the evaporator temperature sensor must be replaced. Failure to do so could result in poor A/C performance. 1. Position the evaporator temperature sensor into the right rear corner of the engine compartment. NOTE: To connect the wire harness connector to the evaporator temperature sensor, first connect the connector to the sensor, then pull the red retaining ring toward the sensor. 2. Connect the wire harness connector to the evaporator temperature sensor. 3. Install the evaporator temperature sensor onto the top of the expansion valve with the sensor probe inserted into the well in the expansion valve. 4. Install the temperature sensor retainer. 5. If equipped with rear A/C, connect the liquid and suction lines to the A/C expansion valve and recharge the A/C system. 6. Install the window wiper module. 7. Install the air cleaner housing into the right side of the engine compartment. 8. Reconnect the negative battery cable. 9. Run the HVAC Cool Down test to verify system is operating properly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > RG Models > Page 7638 Evaporator Temperature Sensor / Switch: Service and Repair RS Models REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel from the vehicle. Evaporator Temperature Sensor - RS Models 3. Disconnect the wire harness connector from the evaporator temperature sensor located on the top of the HVAC housing. 4. Remove the evaporator temperature sensor from the HVAC housing. INSTALLATION 1. Install the evaporator temperature sensor into the top of the HVAC housing. 2. Connect the wire harness connector to the evaporator temperature sensor. 3. Install the instrument panel. 4. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > A/C Pressure Sensor/Switch - Cooling Fan > Component Information > Diagrams A/C Pressure Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation Refrigerant system service ports are used to recover, recycle, evacuate, charge and test the A/C refrigerant system. Unique sizes are used on the two service ports for the R-134a refrigerant system to ensure the system is not accidentally contaminated with R-12 refrigerant or by service equipment used for R-12 refrigerant. The high side service port is located on the front of the liquid line near the receiver/drier. The low side service port is located on the A/C suction line near the A/C compressor. The low side A/C service port valve core is serviceable, however, the high side A/C service port valve core is not. If the high side service port valve core is faulty or damaged, the front of the liquid line will require replacement. NOTE: The protective cap aids in service port sealing and helps protects the refrigerant system from contamination. Remember to always reinstall the protective cap onto the service port when refrigerant system service is complete. Each of the service ports has a threaded plastic protective cap installed over it from the factory. The service port caps are serviceable items. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation > Page 7646 Service Port HVAC: Service and Repair REMOVAL WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. NOTE: The low side A/C service port valve core is serviceable, however, the high side A/C service port valve core is not. If the high side service port valve core is faulty or damaged, the front of the liquid line will require replacement. A/C Service Port-Typical 1. Remove the protective cap from the low side service port located on the suction line near the A/C compressor. 2. Recover the refrigerant from the refrigerant system. 3. Using a Schrader-type valve core tool, remove the valve core from the service port. 4. Install a plug in or tape over the opened service port(s). INSTALLATION 1. Lubricate the low side A/C service port valve core with clean refrigerant oil prior to installation.Use only refrigerant oil of the type recommended for the compressor in the vehicle. 2. Remove the tape or plug from the A/C service port located on the suction line near the A/C compressor. 3. Using a standard Schrader-type valve core tool, install and tighten the replacement valve core into the low side A/C service port. CAUTION: A valve core that is not fully seated in the A/C service port can result in damage to the valve during refrigerant system evacuation and charge. Such damage may result in a loss of system refrigerant while uncoupling the charge adapters. 4. Evacuate the refrigerant system. 5. Charge the refrigerant system. 6. Reinstall the protective cap onto the A/C service port. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System DRIVER AIRBAG After a Driver Airbag has been deployed due to a collision, the following MUST be replaced: - Driver Airbag - Clockspring Assembly - Steering Wheel - Complete Steering Column Assembly w/Lower Steering Column Coupler All other airbag and vehicle components should be closely inspected following any airbag deployment, and should be replaced when visible damage is incurred. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. PASSENGER AIRBAG After a Passenger Airbag has been deployed due to a collision, the following MUST be replaced: - Passenger Airbag - Instrument Panel and Pad Assembly All other airbag and vehicle components should be closely inspected following any airbag deployment, and should be replaced when visible damage is incurred. KNEE BLOCKER AIRBAG After a Knee Blocker Airbag has been deployed due to a collision, the following MUST be replaced: - Knee Blocker Airbag - Instrument Panel and Pad Assembly All other airbag and vehicle components should be closely inspected following any airbag deployment, and should be replaced when visible damage is incurred. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. CURTAIN AIRBAG After a Curtain Airbag has been deployed due to a collision, the following MUST be replaced: - Curtain Airbag Assembly - Headliner - A, B, and C-Pillar Trim on deployed side. All other airbag and vehicle components should be closely inspected following any airbag deployment, and should be replaced when visible damage is incurred. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. OCCUPANT CLASSIFICATION SYSTEM (OCS) After an impact event, either front, rear, or side, the OCS system components need to be inspected and replaced if found to be damaged. This includes: - Belt Tension Sensor - Occupant Classification Module (OCM) - Passenger Airbag ON/Off Indicator - Seat Weight Bladder and Sensor WARNING: NEVER REPLACE BOTH THE OCCUPANT RESTRAINT CONTROLLER (ORC) AND THE OCCUPANT CLASSIFICATION MODULE (OCM) AT THE SAME TIME. IF BOTH REQUIRE REPLACEMENT, REPLACE ONE, THEN PERFORM THE AIRBAG SYSTEM TEST BEFORE REPLACING THE OTHER. BOTH THE ORC AND THE OCM STORE OCCUPANT CLASSIFICATION SYSTEM (OCS) CALIBRATION DATA, WHICH THEY TRANSFER TO ONE ANOTHER WHEN ONE OF THEM IS REPLACED. IF BOTH ARE REPLACED AT THE SAME TIME, AN IRREVERSIBLE FAULT WILL BE SET IN BOTH MODULES AND THE OCS MAY MALFUNCTION AND RESULT IN PERSONAL INJURY OR DEATH. Whether replaced or not, the OCS must be re-zeroed to make sure that the system in within proper parameters to sense the occupants weight correctly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 7652 WARNING: - DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. - FOLLOWING SUCCESSFUL COMPLETION OF THE AIRBAG SYSTEM TEST PROCEDURE, THE OCCUPANT CLASSIFICATION SYSTEM VERIFICATION TEST MUST BE DONE USING A SCAN TOOL AND THE APPROPRIATE DIAGNOSTIC INFORMATION. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED. SEAT BELTS AND TENSIONERS After a frontal impact where an airbag has been deployed due to a collision, the following MUST be replaced: - Front Seat Belt Buckle (driver and passenger) with integral Tensioners. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. All other seat belts should be closely inspected for cuts, tears, fraying, or damage in any way following any frontal impact or airbag deployment. The other seat belts are to be replaced when visible damage is incurred. Inspect the Lower Anchors and Tether for Children (LATCH) child restraint anchors for damage after an impact event and replace as needed. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 7653 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION RESTRAINT SYSTEM After a impact where an airbag has been deployed due to a collision, the following MUST be replaced: 1. Front Seat Belts and Retractors (driver and passenger) with integral Tensioners. 2. After an impact that deploys the airbag, the seat belt tensioner assembly must be replaced. WARNING: WHEN THE FRONT AIRBAG IS DEPLOYED, THE TENSIONER WILL HAVE DEPLOYED ALSO AND MUST BE REPLACED. 3. Do not reuse the bolts attaching the seat belt retractor to the seat frame. Failure to follow proper installation procedure may result in the seat track latch pins not being synchronized. 4. Inspect the condition of the shoulder/lap belt. replace the retractor if the belt is cut, frayed, torn, or damaged in any way. The rear seat back retaining nut also serves as the center seat belt anchor. Be certain to torque this nut. 5. All seat belts should be closely inspected for cuts, tears, fraying, or damage in any way following any frontal impact or airbag deployment. The seat belts are to be replaced when visible damage is incurred. Inspect the Lower Anchors and Tether for Children (LATCH) child restraint anchors for damage after an impact event and replace as needed. 6. During, and following, any child restraint anchor service, due to impact event or vehicle repair, carefully inspect all mounting hardware, tether straps and anchors for proper installation, operation, or damage. if a child restraint anchor is found damaged in any way, the anchor must be replaced with the seat assembly. failure to do so could result in occupant personal injury or death. NOTE: Never attempt to repair a seat belt component. always replace damaged or faulty seat belt components with the correct, new and unused replacement parts. VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS) If any of the Occupant Classification System (OCS) components of the passenger side front seat cushion require replacement, they are serviced only as a factory-calibrated, assembled, and tamper-evident service replacement package. This package includes the assembled frame, springs, pad, seat weight bladder and pressure sensor, foam, wiring and a calibrated OCM. When installing this package, always replace all of the existing components with the new components as a unit. Do not attempt to separate or disconnect any of the new OCS components contained in the service replacement package from each other, and do not attempt to reuse any of the replaced components in this or any other vehicle. CAUTION: Never replace both the Airbag Control Module (ACM) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one. Then perform the supplemental restraint verification test before replacing the other. Both the ACM and the OCM store OCS calibration data, which they transfer to one another when one of them is replaced. If both are replaced at the same time, an irreversible fault will be set in both modules. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 7659 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 7660 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Page 7661 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 7666 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 7667 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 7668 Air Bag: Technical Service Bulletins Air Bag System - Passenger Air Bag Service Precautions NUMBER: 08-001-04 GROUP: Electrical DATE: January 06, 2004 SUBJECT: Front Passenger Airbag Safety Precautions OVERVIEW: This bulletin involves warnings prohibiting modifications to the front passenger seat assembly, related components, or trim cover. MODELS: 2005 (CS) Pacifica 2004 - 2005 (HB) Durango 2004 - 2005 (KJ) Liberty 2005 (LX) 300C, 300N, Magnum 2005 (ND) Dakota 2005 (RS) Caravan, Town & Country 2005 (WK) Grand Cherokee NOTE: This bulletin applies to vehicles equipped with the Occupant Classification System (OCS) for the right front passenger airbag. DISCUSSION: The front passenger seat assembly contains critical components that affect the front passenger airbag deployment. Correctly functioning front passenger seat components are critical for the Occupant Classification System (OCS) to properly classify the front passenger and calculate the proper airbag deployment. Do not make any unapproved modifications to the front passenger seat components, assembly, or to the trim cover. NOTE: Always follow the service information in TechCONNECT for the correct repair and/or diagnostic procedures when servicing the front passenger seat assembly, related parts, or trim cover. Unapproved modifications or service procedures to the front passenger seat assembly, its related components, or trim cover may inadvertently change the airbag deployment in case of a frontal crash. THIS COULD RESULT IN DEATH OR SERIOUS INJURY TO THE FRONT SEAT PASSENGER IF THE VEHICLE IS INVOLVED IN AN ACCIDENT. A modified vehicle may not comply with required Federal Motor Vehicle Safety Standards (FMVSS). The following requirements must be strictly adhered to: 1. DO NOT MODIFY THE FRONT PASSENGER SEAT ASSEMBLY OR COMPONENTS IN ANY WAY. 2. DO NOT MODIFY THE FRONT SEAT CENTER CONSOLE OR CENTER POSITION SEAT IN ANY WAY. 3. DO NOT USE PRIOR OR FUTURE MODEL YEAR SEAT TRIM COVERS NOT DESIGNATED FOR THE SPECIFIC MODEL BEING REPAIRED. ALWAYS USE THE CORRECT SEAT TRIM COVER SPECIFIED FOR THE VEHICLE. 4. DO NOT REPLACE THE SEAT TRIM COVER WITH AN AFTERMARKET TRIM COVER. 5. DO NOT ADD A SECONDARY TRIM COVER OTHER THAN THOSE APPROVED BY DAIMLERCHRYSLER/MOPAR. 6. AT NO TIME SHOULD ANY SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENT OR SRS RELATED COMPONENT OR FASTENER BE MODIFIED OR REPLACED WITH ANY PART EXCEPT THOSE WHICH ARE APPROVED BY DAIMLERCHRYSLER/MOPAR. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 7669 POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 7670 Air Bag: Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 7671 Air Bag: Diagrams C308 (Side Airbag) C308 (Side Airbag) C309 (Side Airbag) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 7672 C309 (Side Airbag) C311 (3 Zone HVAC/Except Side Airbag) C311 (3 Zone HVAC/Except Side Airbag) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 7673 C312 (Side Airbag) C312 (Side Airbag) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 7674 Driver Airbag Squib 1 Driver Airbag Squib 2 Driver Knee Blocker Airbag Squib (LHD) Left Curtain Airbag Squib Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service Bulletins > Page 7675 Passenger Airbag Right Curtain Airbag Squib Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Curtain Airbag Air Bag: Description and Operation Curtain Airbag Curtain Airbag SRS Logo Curtain Airbags are available when it is also equipped with dual front airbags. These airbags are passive and inflatable, Supplemental Restraint System (SRS) components, and vehicles with this equipment can be readily identified by a molded identification trim button with the "SRS - AIRBAG" logo located on the B-pillar and C-pillar upper trim panels. This system is designed to reduce injuries to the vehicle occupants in the event of a side impact collision. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Curtain Airbag > Page 7678 Curtain Airbag Location - Typical Curtain airbags have two individually controlled curtain airbag units. These airbag units are concealed and mounted above the headliner where they are each secured to one of the roof side rails. Each airbag cushion is contained within a fabric wrap that extends along the roof rail from the A-pillar at the front of the vehicle to just behind the D-pillar at the rear of the vehicle. One tether extends down the A-pillar from the front of the airbag cushion, and a second tether extends to the roof rail at the D-pillar. The end of the A-pillar tether is secured to a slot in the sheet metal with a metal hook retained by a bolt. The D-pillar tether is attached to the d-pillar. The hybrid-type inflator for each airbag is secured to the roof rail just behind the C-pillar. The inflator bracket and the airbag cushion are secured with both plastic push-in fasteners and screws to the roof rail. A short pigtail wire harness connects the curtain air-bag inflator to the body wire harness. The curtain airbag cannot be adjusted or repaired and must be replaced if deployed, faulty, or in any way damaged. Once a curtain airbag has been deployed, the complete airbag unit, headliner, upper A/B/C and D-pillar trim, and all other visibly damaged components must be replaced. Head Impact Counter Measures The curtain airbags also contain Head Impact Counter Measures. These injection molded plastic components help to reduce the likelihood of injury or death in the event of a side impact event. They are attached to the curtain airbag and are also used to mount the curtain to the inside roof rail. Their Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Curtain Airbag > Page 7679 purpose is to maintain a flat surface in which the deployed airbag to be pressed against when interior occupants/forces are pushing outwards. Each curtain airbag is deployed individually by an electrical signal generated by the Occupant Restraint Controller (ORC) to which it is connected through left or right curtain airbag line 1 and line 2 (or squib) circuits. The hybrid-type inflator assembly for each airbag contains a small canister of highly compressed inert gas. When the ORC sends the proper electrical signal to the airbag inflator, the electrical energy creates enough heat to ignite chemical pellets within the inflator. Once ignited, these chemicals burn rapidly and produce the pressure necessary to rupture a containment disk in the inert gas canister. The inflator and inert gas canister are sealed and connected to a tubular manifold so that all of the released gas is directed into the folded curtain airbag cushion, causing the cushion to inflate. As the airbag cushion inflates it will drop down from the roof rail between the edge of the headliner and the side glass/body pillars to form a curtain-like cushion to protect the vehicle occupants during a side impact collision. The front and rear tethers keep the side curtain bag taut, thus ensuring that the bag will deploy in the proper position. Following the airbag deployment, the airbag cushion quickly deflates by venting the inert gas through the loose weave of the cushion fabric, and the deflated cushion hangs down loosely from the roof rail. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Curtain Airbag > Page 7680 Air Bag: Description and Operation Driver Airbag The injection molded, thermoplastic driver airbag protective trim cover is the most visible part of the driver airbag. The driver airbag is located in the center of the steering wheel, where it is secured to the steering wheel armature. Concealed beneath the driver airbag trim cover are the horn switch, the folded airbag cushion, the airbag cushion retainer, the airbag housing, the airbag inflator, and the retainers that secure the inflator to the airbag housing. The airbag cushion, housing, and inflator are secured within an integral receptacle molded into the back of the trim cover. The resistive membrane-type horn switch is secured with heat stakes to the inside surface of the driver airbag trim cover, between the trim cover and the folded airbag cushion. The horn switch ground pigtail wire has a female spade terminal connector that receives a path to ground through a male spade terminal that is integral to the driver airbag housing stamping and is located near the upper right corner on the back of the housing. The horn switch feed pigtail wire has a white, molded plastic insulator that is secured by an integral retainer to a mounting hole located near the lower left corner on the back of the housing, and is connected to the vehicle electrical system through a take out and connector of the steering wheel wire harness. The airbag is a multistage unit that deploys with less force than those previously used. The airbag inflator is a dual-initiator, non-azide, pyrotechnic-type unit with four mounting studs and is secured to the stamped metal airbag housing using four hex nuts with washers. Two keyed and color-coded connector receptacles on the driver airbag inflator connect the two inflator initiators to the vehicle electrical system through two yellow or black-jacketed, two-wire pigtail harnesses of the clockspring. The driver airbag, trim cover, and horn switch unit cannot be repaired, and must be replaced if deployed or in any way damaged. The Driver Airbag Trim Cover contains the horn switch, inflator device, and a fabric bag. The driver airbag trim cover/horn switch is not serviced separately from the driver airbag components. When the front airbag system is deployed, the following MUST be replaced: - Complete Steering Column Assembly - Lower Steering Column Coupler - Steering Wheel. - Clockspring. - Driver Airbag - Passenger Airbag - Knee Blocker Airbag - Upper Instrument Panel with Pad - Front Seat Belt Buckles, both driver and passenger with integral tensioners. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Curtain Airbag > Page 7681 Air Bag: Description and Operation Knee Blocker Airbag Knee Blocker Airbag Knee Blocker Airbag Location The Knee Blocker Airbag is located on the driver side of the vehicle beneath the instrument panel under steering column cover. The knee blocker airbag includes one reaction plate and one load plate, within which the cushion and inflator are mounted and sealed. Following a knee blocker airbag deployment, the knee blocker airbag and instrument panel assembly must be replaced. The knee blocker airbag is equipped with a single inflator. When the Occupant Restraint Controller (ORC) sends the proper electrical signals to the initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the back of the airbag housing and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the knee blocker airbag trim deploy. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas towards the instrument panel through vent holes within the fabric used to construct the back panel of the airbag cushion. Some of the chemicals used to create the inert gas may be considered hazardous while in their solid state before they are burned, but they are securely sealed within the airbag inflator. Typically, the potentially hazardous chemicals are burned during an air-bag deployment event. WARNING: THE INERT GAS THAT IS PRODUCED WHEN THE CHEMICALS ARE BURNED IS HARMLESS. HOWEVER, A SMALL AMOUNT OF RESIDUE FROM THE BURNED CHEMICALS MAY CAUSE SOME TEMPORARY DISCOMFORT IF IT CONTACTS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Curtain Airbag > Page 7682 THE SKIN, EYES, OR BREATHING PASSAGES. IF SKIN OR EYE IRRITATION IS NOTED, RINSE THE AFFECTED AREA WITH PLENTY OF COOL, CLEAN WATER. IF BREATHING PASSAGES ARE IRRITATED, MOVE TO ANOTHER AREA WHERE THERE IS PLENTY OF CLEAN, FRESH AIR TO BREATH. IF THE IRRITATION IS NOT ALLEVIATED BY THESE ACTIONS, CONTACT A PHYSICIAN. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Curtain Airbag > Page 7683 Air Bag: Description and Operation Passenger Airbag WARNING: NEVER DISASSEMBLE THE PASSENGER AIR-BAG. THE PASSENGER AIRBAG HAS NO SERVICEABLE PARTS. IF TAMPERED WITH INTERNALLY, THE AIRBAG COULD DEPLOY AND RESULT IN PERSONAL INJURY OR DEATH. The Passenger Airbag is located beneath the instrument panel and pad assembly. The airbag is mounted to the back side of the instrument panel reinforcement. The instrument panel top pad is the most visible part of the passenger airbag system. Located under the instrument panel top pad are the airbag door, the passenger airbag cushion and the airbag cushion supporting components. The passenger airbag includes a magnesium housing within which the cushion and inflator are mounted and sealed. Following a passenger airbag deployment, the passenger airbag and the instrument panel must be replaced. The passenger airbag cannot be repaired, and must be replaced if deployed or damaged in any way. The passenger airbag is equipped with two inflators, each with three levels of pressure output. The inflators seal the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the proper electrical signal. Following an airbag deployment, the airbag cushion quickly deflates by venting this gas through the cushion material towards the instrument panel. The passenger airbag is secured with screws to the instrument panel beneath the instrument panel top pad and above the glove box opening. The instrument panel top pad above the glove box opening conceals the airbag door and a predetermined hinge line beneath its decorative cover. Upon airbag deployment, the top pad will bend at the hinge line and the door will fold back out of the way onto the top of the instrument panel. When the front airbag system is deployed, the following MUST be replaced: - Complete Steering Column Assembly. - Lower Steering Column Coupler. - Steering Wheel. - Clock Spring. - Driver Airbag. - Passenger Airbag. - Upper Instrument Panel with Pad. CARE OF UNDEPLOYED AIRBAGS Airbags must be stored in their original special container until used for service. At no time should a source of electricity be permitted near the inflator on the back of an airbag. When carrying or handling an undeployed airbag, the trim side of the airbag should be pointing away from the body to minimize possibility of injury if accidental deployment occurs. Do not place undeployed airbag face down on a solid surface, the airbag will propel into the air if accidental deployment occurs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Curtain Airbag Air Bag: Service and Repair Curtain Airbag REMOVAL 1. Open hood, disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG SYSTEM OR COMPONENT SERVICE. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, PERSONAL INJURY OR DEATH. 2. Remove the headliner from the vehicle. Curtain Airbag Squib Connection 3. Disconnect the curtain airbag squib connector. Curtain Airbag Front Tether Attachment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Curtain Airbag > Page 7686 4. Remove the bolt from the curtain airbag front tether and unclip from the A-pillar. Curtain Airbag Remove/Install 5. Remove the screws that secure the curtain air-bag to the spring nuts in the roof side rail. Curtain Airbag Inflator Mounting Bracket Attachment 6. Remove the bolt from the curtain airbag inflator mounting bracket. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Curtain Airbag > Page 7687 Curtain Airbag D-Pillar Attachment 7. Remove the bolts retaining the curtain airbag to the roof rail in the d-pillar area. 8. Grasp the curtain airbag, using a trim stick (special tool #C-4755) or equivalent, gently pry out on push fasteners to disengage the curtain airbag and remove it from its mounting location in the side roof rail. 9. Remove the curtain airbag from the vehicle as a unit. INSTALLATION 1. Position curtain airbag over retaining holes in roof rail and firmly snap into place. 2. Install the curtain airbag retaining bolts. 3. Engage the side curtain airbag front tether in the a-pillar and install retaining bolt. 4. Install the bolt in the curtain airbag inflator mounting bracket. 5. Install the retaining bolts at the d-pillar. 6. Connect the curtain airbag squib connector. 7. Install the headliner into the vehicle. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. 8. Verify vehicle and system operation. 9. Close hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Curtain Airbag > Page 7688 Air Bag: Service and Repair Driver Airbag Deployed Airbag REMOVAL 1. Clean powder residue from interior of vehicle. 2. Position steering wheel and front wheels straight ahead. 3. Release hood latch and open hood. 4. Disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG SYSTEM OR COMPONENT SERVICE. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, PERSONAL INJURY OR DEATH. 5. Remove two screws retaining driver airbag to steering wheel. 6. Disconnect wire connectors from back of driver airbag. 7. Disconnect the 2-way connector from remote radio control harness. 8. Disconnect the 4-way harness connector from the speed control/horn harness to the clockspring. 9. Remove steering wheel. 10. Remove steering column shrouds and disconnect traction control wire connector (if equipped). 11. Disconnect 4-way and 6-way connectors between the clockspring and the instrument panel wiring harness. 12. Remove clockspring from column assembly by removing the two retaining screws that attach the clockspring to the column. WARNING: THE CLOCKSPRING, STEERING WHEEL, AND COMPLETE STEERING COLUMN ASSEMBLY W/LOWER STEERING COLUMN COUPLER MUST BE REPLACED ALSO IN THE EVENT OF A DRIVER AIRBAG DEPLOYMENT. PERSONAL INJURY OR DEATH MAY RESULT IF NOT REPLACED. INSTALLATION 1. Perform clean up procedure. 2. Install a new steering column assembly and lower steering column coupler. 3. Install the new clockspring. 4. Connect the 4-way and 6-way connectors between the clockspring and the instrument panel wiring harness. 5. Install the steering column shrouds and connect traction control wire connector (if equipped). 6. Install the steering wheel. 7. Connect the 4-way harness connector to the speed control/horn harness to the clockspring. 8. Connect the 2-way connector to the remote radio control harness. 9. Install the driver airbag and the two screws retaining the airbag. Tighten screws to 10 Nm (90 in. lbs.) WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. Undeployed Airbag REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG COMPONENT SERVICE. PERSONAL INJURY OR DEATH MAY RESULT. 3. Remove two screws retaining driver airbag to steering wheel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Curtain Airbag > Page 7689 Driver Airbag Wire Connections 4. Disconnect wire connectors from back of driver airbag. 5. Disconnect the 2-way connector from remote radio control harness. 6. Disconnect the 4-way harness connector from the speed control/horn harness to the clockspring. 7. Remove driver airbag from vehicle. WARNING: WHEN CARRYING OR HANDLING AN UNDEPLOYED AIRBAG, THE TRIM SIDE OF THE AIRBAG SHOULD BE POINTING TOWARD THE BODY TO MINIMIZE THE POSSIBILITY OF INJURY IF ACCIDENTAL DEPLOYMENT OCCURS. DO NOT PLACE UNDEPLOYED AIRBAG FACE DOWN ON A SOLID SURFACE, THE AIRBAG WILL PROPEL INTO THE AIR IF ACCIDENTAL DEPLOYMENT OCCURS. FAILURE TO DO THIS MAY RESULT IN PERSONAL INJURY OR DEATH. INSTALLATION 1. Connect the harness connector on the driver airbag trim cover (horn, speed controls) to the clock-spring. 2. Connect the squib connectors to the driver air-bag. 3. Position the driver airbag into the steering wheel. 4. Install the two screws retaining the airbag. Tighten screws to 10 Nm (90 in. lbs.) WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Curtain Airbag > Page 7690 Air Bag: Service and Repair Passenger Airbag Deployed Airbag REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG SYSTEM OR COMPONENT SERVICE. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, PERSONAL INJURY OR DEATH. 3. Clean powder residue from interior of vehicle. 4. Remove instrument panel. 5. Remove all reusable components from the upper instrument panel and transfer to the new instrument panel. INSTALLATION Transfer all reusable components to the new instrument panel. 1. Install new Passenger Airbag into instrument panel. 2. Install airbag attaching bolts to the instrument panel. a. Torque the two bolts at instrument panel retainer bosses to 2.7 ± .5 Nm (24 ± 5 in. lbs.). b. Torque the three bolts that attach the passenger airbag to cross-car beam to 10 ± 2 Nm (90 ± 15 in. lbs.). 3. Connect yellow wire connector to passenger air-bag and affix connector to instrument panel reinforcement with push pins. 4. Install Instrument panel. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. Undeployed Airbag REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG SYSTEM OR COMPONENT SERVICE. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, PERSONAL INJURY OR DEATH. 3. Remove center console bin between front seats. 4. Remove left front door sill plate using a trim stick (special tool #C-4755) or equivalent, and gently prying up on sill plate. 5. Remove left cowl panel using a trim stick or equivalent, and gently prying out on cowl panel. 6. Remove four screws to lower steering column cover and remove cover. 7. Unsnap parking brake lever from knee blocker reinforcement. 8. Remove Data Link Connector (DLC) from knee blocker. 9. Remove screws to knee blocker. 10. Unsnap left A-pillar lower extension trim using a trim stick or equivalent. 11. Remove three left side instrument panel A-pillar retaining bolts and loosen the instrument panel roll down bolt. 12. Remove four nuts at brake pedal support bracket to instrument panel. 13. Using a trim stick or equivalent, gently pry off left side upper A-pillar trim. 14. Remove six screws and two wiring connectors to lower instrument panel cubby bin at bottom of center stack. 15. Remove two left side nuts at instrument panel center stack support to floor. 16. Remove two right side nuts at instrument panel center stack support to floor. 17. Remove right front door sill plate using a trim stick or equivalent, and gently prying up on sill plate. 18. Remove right cowl panel using a trim stick or equivalent, and gently prying out on cowl panel. 19. Using a trim stick or equivalent, gently pry out on right instrument panel end cap. 20. Unsnap right A-pillar lower extension trim using a trim stick or equivalent. 21. Remove three right side instrument panel A-pillar retaining bolts and loosen the instrument panel roll down bolt. 22. Using a trim stick or equivalent, gently pry off right side upper A-pillar trim. 23. Open glove box, pinch in sides and roll down towards floor. With a firm pull, snap glove box door off hinges and remove. 24. Using a trim stick or equivalent, gently pry up on rear of instrument panel top cover and then pull rearward and out. 25. Using a trim stick or equivalent, gently pry off the filler bezel just above the cup holder to expose the lower screws to center bezel. 26. Remove two screws and then using a trim stick or equivalent, gently pry off instrument panel center bezel. 27. Remove center bezel wiring connectors to HVAC control and switch assembly (hazard, rear wiper/washer, heated seats) and remove bezel. 28. Slide cup holder assembly from instrument panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Curtain Airbag > Page 7691 29. Remove nineteen screws to right lower instrument panel trim (glove box surround), unplug glove box lamp wire connector, and remove panel. 30. Remove four screws and wiring connectors to radio and remove radio. 31. Remove one far left instrument panel speaker retaining screw. 32. Remove four screws along top front edge of instrument panel cover/pad. 33. Remove seven lower instrument panel cover/ pad retaining screws starting from right of vehicle and only removing these seven, not all of them. 34. Remove six upper fence line instrument panel retaining bolts. 35. Roll back instrument panel just enough to increase access to the passenger airbag retaining bolts at the reinforcement. Lift the instrument panel up slightly so as not to damage the air distribution to HVAC unit seal. 36. Disconnect the passenger airbag electrical connector. Using a trim stick or equivalent, gently pry electrical connector off of instrument panel reinforcement. 37. Remove the two passenger airbag to instrument panel cover/pad retaining screws. 38. Remove the three passenger airbag to instrument panel reinforcement retaining bolts. 39. Pull rearward slightly on the instrument panel cover/pad to maneuver passenger airbag out from reinforcement and instrument panel. INSTALLATION 1. Pull rearward slightly on the instrument panel cover/pad to maneuver passenger airbag up onto reinforcement and instrument panel. 2. Install the three passenger airbag to instrument panel reinforcement retaining bolts but leave loose. This will help align the passenger airbag for the cover/pad fit. 3. Install the two passenger airbag to instrument panel cover/pad retaining screws. Torque screws to 2.7 ± 5 Nm (24 ± 5 in. lbs.). NOTE: Insure that the instrument panel cover/pad locator pins are indexed properly at center stack area prior to reassembly. 4. Tighten the three passenger airbag to instrument panel reinforcement retaining bolts. Torque bolts to 10 ± 2 Nm (90 ± 15 in. lbs.). 5. Connect the passenger airbag electrical connector. Install the connector onto the instrument panel reinforcement with the push-pin fasteners. 6. Roll the instrument panel forward lifting slightly so as to seat the instrument panel air distribution duct on top of the HVAC unit properly to avoid any leaks or damage to the seal. 7. Install six upper fence line instrument panel retaining bolts. 8. Install three right side instrument panel A-pillar retaining bolts and tighten the right instrument panel roll down bolt. Install the smaller 10 mm bolt first to align the instrument panel properly. 9. Install three left side instrument panel A-pillar retaining bolts and tighten the left instrument panel roll down bolt. Install the smaller 10 mm bolt first to align the instrument panel properly. 10. Install seven lower instrument panel cover/ pad retaining screws. 11. Install four screws along top front edge of instrument panel cover/pad. 12. Install one far left instrument panel speaker retaining screw. 13. Install wiring connectors to radio. Install radio and four retaining screws. 14. Connect glove box lamp wiring connector and place right lower instrument panel trim (glove box surround) into position. 15. Install nineteen right lower instrument panel trim (glove box surround) and install panel screws. 16. Slide cup holder assembly into instrument panel. 17. Install center bezel wiring connectors to HVAC control and switch assembly (hazard, rear wiper/washer, heated seats). 18. Install instrument panel center bezel by aligning slots and firmly snapping into place. 19. Install two screws to instrument panel center bezel. 20. Align filler bezel above cup holder over retaining slots and firmly snap into place. 21. Place instrument panel top cover into position and firmly snap down rear edge of top cover. 22. Install glove box. Align hinges, snap into place, roll glove box upwards and push in sides to fully install. 23. Align right side upper A-pillar trim over retaining slots and firmly snap into place. 24. Align right A-pillar lower extension trim over retaining slots and firmly snap into place. 25. Align right instrument panel end cap over retaining slots and firmly snap into place. 26. Align right cowl panel over retaining slots and firmly snap into place. 27. Align right front door sill plate over retaining slots and firmly snap into place. 28. Install two right side nuts at instrument panel center stack support to floor. 29. Install two left side nuts at instrument panel center stack support to floor. 30. Connect the two wiring connectors to lower instrument panel cubby bin at bottom of center stack and install six screws. 31. Align left side upper A-pillar trim over retaining slots and firmly snap into place. 32. Install four nuts at brake pedal support bracket to instrument panel. 33. Align left A-pillar lower extension trim over retaining slots and firmly snap into place. 34. Install knee blocker and retaining screws. 35. Install Data Link Connector (DLC) into bottom of knee blocker. 36. Align parking brake lever and snap into place on knee blocker reinforcement. 37. Install lower steering column cover and four retaining screws 38. Align left cowl panel over retaining slots and firmly snap into place. 39. Align left front door sill plate over retaining slots and firmly snap into place. 40. Install center console bin between front seats. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Curtain Airbag > Page 7692 41. Close hood. 42. Verify system and vehicle operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Curtain Airbag > Page 7693 Air Bag: Service and Repair Knee Blocker Airbag REMOVAL 1. Open hood, disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG SYSTEM OR COMPONENT SERVICE. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, PERSONAL INJURY OR DEATH. Steering Column Opening Cover 2. Remove the steering column opening cover two retaining screws and unsnap cover from instrument panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Curtain Airbag > Page 7694 Knee Blocker Airbag Electrical Connector 3. Disconnect the knee blocker airbag electrical connector. Knee Blocker Airbag - Remove/Install 4. Remove five knee blocker airbag retaining bolts from airbag. 5. Remove knee blocker airbag from vehicle. INSTALLATION 1. Place the knee blocker airbag into position in the instrument panel opening. 2. Connect the one electrical connector. 3. Install the five knee blocker airbag retaining bolts. 4. Position the steering column opening cover over retaining slots and firmly snap into place. Install the two retaining screws. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST 5. Verify vehicle and system operation. 6. Close hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7698 Air Bag Control Module: Diagrams Occupant Restraint Controller C1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7699 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7700 Occupant Restraint Controller C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7701 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7702 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7703 Air Bag Control Module: Description and Operation Occupant Restraint Controller - Typical The Occupant Restraint Controller (ORC) is also sometimes referred to as the Airbag Control Module (ACM). ORC Location The ORC is secured with screws to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel just behind and underneath the instrument panel center stack in the passenger compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with four screws to enclose and protect the internal electronic circuitry and components. An arrow printed on the label on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has integral mounting flanges, the ORC has two molded plastic electrical connectors that exits the right facing side of the ORC housing. These terminal pins connect the ORC to the vehicle electrical system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7704 The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for vehicles with or without curtain airbags. The ORC cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The microprocessor in the Occupant Restraint Controller (ORC) contains the supplemental restraint system logic circuits and controls all of the supplemental restraint system components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Programmable Communication Interface (PCI) data bus. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and for supplemental restraint system diagnosis and testing through the 16-way Data Link Connector (DLC) located on the driver side lower edge of the instrument panel. The ORC microprocessor continuously monitors all of the supplemental restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the PCI data bus to turn on the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTC's, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. On models equipped with the Occupant Classification System (OCS), the ORC communicates with the Occupant Classification Module (OCM) over the PCI data bus. The ORC will internally disable the passenger airbag and seat belt tensioner deployment circuits if the OCM detects that the passenger side front seat is unoccupied or that it is occupied by a load that is inappropriate for an airbag deployment. The ORC also provides a control output to the Passenger Airbag Disabled (PAD) indicator through the passenger airbag indicator driver circuit. The OCM notifies the ORC when it has detected a monitored system fault and stored a DTC in its memory for any faulty OCS component or circuit, then the ORC sets a DTC and controls the airbag indicator operation accordingly. The ORC receives battery current through two circuits; a fused ignition switch output (RUN) circuit through a fuse in the Junction Block (JB), and a fused ignition switch output (RUN/START) circuit through a second fuse in the JB. The ORC receives ground through a ground circuit of the instrument panel wire harness. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the front supplemental restraint components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup supplemental restraint system protection in case there is a loss of battery current supply to the ORC during an impact. Two sensors are contained within the ORC, an electronic impact sensor and a safing sensor. The ORC also monitors inputs from eight remote impact sensors. Two front impact sensors are located on each outboard side of the lower radiator support, and three side impact sensors are located on each side of the vehicle at the B-pillar, in the lower sliding door opening in front of the C-pillar, and over the rear wheel well between the C and D-pillars. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The safing sensor is an electronic accelerometer sensor within the ORC that provides an additional logic input to the ORC microprocessor. The safing sensor is used to verify the need for a supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with curtain airbags, there is a second safing sensor within the ORC to provide confirmation to the ORC microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require supplemental restraint system protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either curtain airbag. For vehicles equipped with the OCS, the passenger front airbag and seat belt tensioner will be deployed by the ORC only if enabled by the OCM messages (PAD indicator OFF) at the time of the impact. To diagnose and test the ORC and all airbag system components, use a scan tool and the appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7705 Air Bag Control Module: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS), NEVER REPLACE BOTH THE OCCUPANT RESTRAINT CONTROLLER (ORC) AND THE OCCUPANT CLASSIFICATION MODULE (OCM) AT THE SAME TIME. IF BOTH REQUIRE REPLACEMENT, REPLACE THE OCM FIRST. THEN PERFORM THE AIRBAG SYSTEM TEST INCLUDING AN IGNITION-ON TIME OF AT LEAST ONE MINUTE BEFORE REPLACING THE ORC. BOTH THE ORC AND THE OCM STORE OCS CALIBRATION DATA, WHICH THEY TRANSFER TO ONE ANOTHER DURING THE FIRST MINUTE OF IGNITION-ON TIME AFTER ONE OF THEM IS REPLACED. IF BOTH MODULES ARE REPLACED AT THE SAME TIME, AN IRREVERSIBLE FAULT WILL BE SET IN BOTH MODULES. 1. Disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG SYSTEM OR COMPONENT SERVICE. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, PERSONAL INJURY OR DEATH. 2. Remove storage bin from instrument panel. ORC - Remove/Install 3. Remove three bolts holding ORC to floor bracket. 4. Disconnect the wire connectors from the ORC. 5. Remove the ORC from vehicle. INSTALLATION WARNING: - DO NOT INSTALL ORC IF MOUNTING LOCATION IS DEFORMED OR DAMAGED. THIS WILL CAUSE THE ORC TO BE IMPROPERLY LOCATED AND COULD RESULT IN OCCUPANT PERSONAL INJURY OR DEATH. - USE CORRECT SCREWS WHEN INSTALLING THE ORC. - NEVER REPLACE BOTH THE OCCUPANT RESTRAINT CONTROLLER (ORC) AND THE OCCUPANT CLASSIFICATION MODULE (OCM) AT THE SAME TIME. IF BOTH REQUIRE REPLACEMENT, REPLACE ONE, THEN PERFORM THE AIRBAG SYSTEM TEST BEFORE REPLACING THE OTHER. BOTH THE ORC AND THE OCM STORE OCCUPANT CLASSIFICATION SYSTEM (OCS) CALIBRATION DATA, WHICH THEY TRANSFER TO ONE ANOTHER WHEN ONE OF THEM IS REPLACED. IF BOTH ARE REPLACED AT THE SAME TIME, AN IRREVERSIBLE FAULT WILL BE SET IN BOTH MODULES AND THE OCS MAY MALFUNCTION AND RESULT IN PERSONAL INJURY OR DEATH. 1. Install the ORC into vehicle. 2. Connect the wire connector to the ORC. 3. Install three bolts holding ORC to floor bracket. Torque bolts to 7.3 - 9.6 Nm (65 to 85 in. lbs.) 4. Install the storage bin onto the instrument panel. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7706 SYSTEM TEST IS NOT PERFORMED FIRST. 5. Verify vehicle and system operation. 6. Close hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Application and ID Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Application and ID > Page 7710 Air Bag Deactivation Indicator: Description and Operation PASSENGER AIRBAG DISABLED INDICATOR Passenger Airbag Disabled (PAD) Indicator Vehicles equipped with the Occupant Classification System (OCS) include a Passenger Air bag Disabled (PAD) indicator which is located in the instrument panel center stack, above the radio. The PAD indicator is present only in vehicles equipped with the OCS. The PAD indicator consists of a molded plastic housing with an integral connector at the back. An amber Light Emitting Diode (LED) behind the lens causes the "PASS AIR BAG OFF" text and icon to appear silhouetted against an amber field through the translucent lens when the indicator is illuminated from behind by the LED. The PAD indicator is available for separate service replacement. In vehicles equipped with the Occupant Classification System (OCS), the Passenger Airbag Disabled (PAD) indicator gives an indication when the passenger airbag and seat belt tensioner deployment circuits are disabled by the Occupant Restraint Controller (ORC). The PAD indicator is controlled by a transistor within the ORC through a hard wired output based upon ORC programming and electronic occupant classification messages received by the ORC over the Programmable Communications Interface (PCI) data bus from the Occupant Classification Module (OCM). The PAD indicator Light Emitting Diode (LED) is completely controlled by the ORC. The LED receives a battery current input on the fused ignition switch output (RUN/START) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the ORC transistor. The ORC will turn on the PAD indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the PAD indicator is illuminated for about six seconds. - Child Seat Detected Occupant Classification Message - Each time the ORC receives a message from the OCM indicating a child seat has been detected in the passenger front seat, the passenger airbag and seat belt tensioner deployment circuits are deactivated and the PAD indicator will be illuminated. The indicator remains illuminated until the ORC receives an occupant classification message indicating that: The passenger front seat is empty. - The seat is occupied by a load equal to or greater than a fifth percentile female. - OR, Until the ignition switch is turned to the OFF position, whichever of these three occurs first. - Load Less Than Fifth Percentile Female Occupant Classification Message - Each time the ORC receives a message from the OCM indicating that a load less than a fifth percentile female has been detected in the passenger front seat, the passenger airbag and seat belt tensioner deployment circuits are deactivated and the PAD indicator will be illuminated. The indicator remains illuminated until: The ORC receives an occupant classification message indicating that the passenger front seat is empty. - The seat is occupied by a load equal to or greater than a fifth percentile female. - OR, until the ignition switch is turned to the OFF position, whichever of these three occurs first. - Load Undetermined Occupant Classification Message - Each time the ORC receives a message from the OCM indicating that a load cannot be determined in the passenger front seat, the passenger airbag and seat belt tensioner deployment circuits are deactivated and the PAD indicator will be illuminated. The indicator remains illuminated until: The ORC receives an occupant classification message indicating that the passenger front seat is empty. - The seat is occupied by a load equal to or greater than a fifth percentile female. - OR, until the ignition switch is turned to the OFF position, whichever of these three occurs first. - Communication Error - If the ORC receives invalid occupant classification messages or no messages from the OCM, the PAD indicator is illuminated. The indicator remains illuminated until: The ORC receives an occupant classification message indicating that the passenger front seat is empty. - The seat is occupied by a load equal to or greater than a fifth percentile female. - OR, until the ignition switch is turned to the OFF position, whichever of these three occurs first. The ORC continually monitors the occupant classification messages from the OCM to decide whether the passenger airbag and seat belt tensioner deployment circuits should be activated or deactivated. Note that there may be several seconds of delay between changes in the detected occupant status and PAD indications. This is a programmed feature of the OCM used to prevent a flashing indicator condition resulting from the normal shifting of occupant weight on the passenger seat cushion. The ORC then provides the proper control output to turn the PAD indicator ON or OFF. The ORC will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. For proper diagnosis of the OCM, the ORC, the PCI data bus, or the electronic message inputs to the ORC that control the PAD indicator, use a scan tool and the appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Indicator > Component Information > Application and ID > Page 7711 Air Bag Deactivation Indicator: Service and Repair PASSENGER AIRBAG DISABLED INDICATOR REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG SYSTEM OR COMPONENT SERVICE. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, PERSONAL INJURY OR DEATH. 3. Remove instrument panel center bezel. 4. From the back of the center bezel, depress the two latches toward the indicator housing and push the indicator out through the face of the center bezel. INSTALLATION 1. From the face of the instrument panel center bezel, align the Passenger Airbag Disabled (PAD) indicator housing with the mounting hole. 2. Firmly push the indicator into the center bezel until the two latches are fully engaged on the back of the cap and are snapped in. 3. Install the instrument panel center bezel. WARNING: - DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. - FOLLOWING SUCCESSFUL COMPLETION OF THE AIRBAG SYSTEM TEST PROCEDURE, THE OCCUPANT CLASSIFICATION SYSTEM VERIFICATION TEST MUST BE DONE USING A SCAN TOOL AND THE APPROPRIATE DIAGNOSTIC INFORMATION. 4. Close hood. 5. Verify system and vehicle operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7715 Clockspring Assembly / Spiral Cable: Diagrams Clockspring C1 Clockspring C2 Clockspring C3 Clockspring C4 (Remote Audio) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7716 Clockspring Assembly / Spiral Cable: Description and Operation The clockspring is mounted on the steering column behind the steering wheel. It is used to maintain a continuous electrical circuit between the wiring harness and the drivers airbag. The clockspring assembly is secured with two integral plastic latches onto the upper steering column housing near the top of the steering column behind the steering wheel. The clockspring consists of a flat, round molded plastic case with a stubby tail that hangs below the steering column. The tail contains two connectors that face toward the instrument panel. Within the plastic case is a spool-like molded plastic rotor with a large exposed hub and several plastic rollers. A rubber bumper block is located on each side of the tower formation that contains the connector receptacle and pigtail wires on the upper surface of the rotor hub. The lower surface of the rotor hub has a molded plastic turn signal cancel cam with a single lobe that is integral to the rotor. Within the plastic case and wound around the rotor spool is a long ribbon-like tape that consists of several thin copper wire leads sandwiched between two thin plastic membranes. The outer end of the tape terminates at the connector receptacles that face the instrument panel, while the inner end of the tape terminates at the pigtail wires and connector receptacle on the hub of the clockspring rotor that face the steering wheel. Service replacement clocksprings are shipped pre-centered and with a molded plastic shield that snaps onto the rotor over the release button. The release button secures the centered clockspring rotor to the clockspring case and the shield prevents the release button from being inadvertently depressed during shipment and handling, but the shield must be removed from the clockspring after it is installed on the steering column. The clockspring cannot be repaired. If the clock-spring is faulty, damaged, or if the driver airbag has been deployed, the clockspring must be replaced. The clockspring is a mechanical electrical circuit component that is used to provide continuous electrical continuity between the fixed instrument panel wire harness and the electrical components mounted on or in the rotating steering wheel. The rotating electrical components include the driver airbag, the horn switch, the speed control switches, and the remote radio switches, if the vehicle is so equipped. The clockspring case is positioned and secured to the upper steering column housing near the top of the steering column. The connector receptacles on the tail of the clockspring case connect the clockspring to the vehicle electrical system through two connectors from the instrument panel wire harness. The clockspring rotor is movable and is keyed by the tower formation that is molded onto the upper surface of the rotor hub to an opening that is cast into the steering wheel armature. Rubber bumper blocks on either side of the clockspring tower formation eliminate contact noise between the clockspring tower and the steering wheel. The lobe of the turn signal cancel cam on the lower surface of the clock-spring rotor hub contacts a turn signal cancel actuator of the multi-function switch to provide automatic turn signal cancellation. The yellow or black-sleeved pigtail wires on the upper surface of the clockspring rotor connect the clockspring to the driver airbag, while a steering wheel wire harness connects the connector receptacle on the upper surface of the clockspring rotor to the horn switch and, if the vehicle is so equipped, to the optional speed control switches and remote radio switches on the steering wheel. The clockspring tape has travel limits and can be damaged by being wound too tightly during full stop-to-stop steering wheel rotation. To prevent this from occurring, the clockspring is centered when it is installed on the steering column. Centering the clock-spring indexes the clockspring tape to the movable steering components so that the tape can operate within its designed travel limits. However, if the clockspring is removed from the steering column or if the steering shaft is disconnected from the steering gear, the clockspring spool can change position relative to the movable steering components and must be re-centered following completion of the service or the tape may be damaged. Service replacement clocksprings are shipped pre-centered and with a plastic shield installed over the clockspring release button. This shield should not be removed and the release button should not be depressed until the clockspring has been installed on the steering column. If the release button is depressed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Clockspring Centering Clockspring Assembly / Spiral Cable: Service and Repair Clockspring Centering If the rotating tape (wire coil) in the clockspring is not positioned properly with the steering wheel and the front wheels, the clockspring may fail. The following procedure MUST BE USED to center the clockspring if it is not known to be properly positioned, or if the front wheels were moved from the straight ahead position. 1. Position steering wheel and front wheels straight ahead. 2. Release hood latch and open hood. 3. Disconnect and isolate the battery negative cable. 4. Wait two minutes for the system reserve capacitor to discharge before beginning any airbag component service. 5. Remove driver airbag from steering wheel. 6. Disconnect wire connectors from back of driver airbag. 7. Disconnect the 2-way connector from remote radio control harness (if equipped). 8. Disconnect the 4-way harness connector from the speed control (if equipped)/horn harness to the clockspring. 9. Remove steering wheel. 10. Rotate the clockspring rotor clockwise until the rotor stops. Do not apply excessive force. 11. From the end of travel, rotate the rotor two turns counter clockwise until the wires end up at the top. 12. Install the steering wheel. 13. Connect the 4-way harness connector to the speed control/horn harness to the clockspring. 14. Connect the 2-way connector to the remote radio control harness. 15. Install the driver airbag. Torque the two screws to 10 Nm (90 in. lbs.). WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED PROPERLY. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Clockspring Centering > Page 7719 Clockspring Assembly / Spiral Cable: Service and Repair Removal and Installation REMOVAL 1. Position steering wheel and front wheels straight ahead. 2. Release hood latch and open hood. 3. Disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG SYSTEM OR COMPONENT SERVICE. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, PERSONAL INJURY OR DEATH. 4. Remove driver airbag from steering wheel. 5. Disconnect wire connectors from back of driver airbag. 6. Disconnect the 2-way connector from remote radio control harness. 7. Disconnect the 4-way harness connector from the speed control/horn harness to the clockspring. 8. Remove steering wheel. 9. Remove steering column shrouds and disconnect traction control wire connector (if equipped) 10. Disconnect 4-way and 6-way connectors between the clockspring and the instrument panel wiring harness. 11. Remove clockspring from column assembly by removing the two retaining screws that attach the clock spring to the column. INSTALLATION 1. Install the clockspring on the column. 2. Connect the 4-way and 6-way connectors between the clockspring and the instrument panel wiring harness. 3. Install the steering column shrouds and connect traction control wire connector (if equipped). 4. Install the steering wheel. 5. Connect the 4-way harness connector to the speed control/horn harness to the clockspring. 6. Connect the 2-way connector to the remote radio control harness (if equipped). 7. Install the driver airbag. Torque the two screws to 10 Nm (90 in. lbs.). WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement Technical Service Bulletin # J38 Date: 100420 Campaign - Front Air Bag Sensor Replacement April 2010 Dealer Service Instructions for: Customer Satisfaction Notification J38 Supplemental Front Airbag Sensors Models 2005-2006 (RS) Dodge Caravan, Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles built from January 19, 2005 through April 5, 2006 (MDH 011900 through 040500). IMPORTANT: Many of the vehicles within the above build period have already been repaired according to our warranty records, and therefore, have been excluded from this notification. Only the above vehicles originally sold or currently registered in certain states are involved. See the "Owner Notification and Service Scheduling" section for a list of states involved in this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The supplemental front airbag sensors on about 310,000 of the above vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Repair The right and left supplemental front airbag sensors must be replaced and the sensor wiring harness connectors must be inspected and replaced, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7728 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7729 Parts Information Special Tools The following special tools may be required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7730 Use the labor operation numbers and time allowances as shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicableable. Only vehicles originally sold or currently registered in the following states are involved in this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7731 To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure A. Supplemental Front Airbag Sensor Replacement 1. Lower the driver's window completely. 2. Open the hood. 3. Disconnect and isolate the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Raise the vehicle on a suitable hoist. 5. Disconnect the wiring harness connector to the right and left supplemental front airbag sensor. The sensors are located on the outside of the right and left frame rails at the radiator lower crossmember (Figure 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7732 6. Remove the right and left supplemental front airbag sensors and discard the sensors and retaining bolts. CAUTION: If the retaining bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose from the radiator lower crossmember. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensor retaining bolts, continue with Step 9. 7. Use the following procedure, if required, to replace a spun riv-nut: a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps. b. Remove the four screws (two each side) that secure the left and right wheelhouse splash shield to the front fascia. c. Remove the right and left side fascia-to-fender bolts. d. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. e. Partially lower the vehicle. f. Remove the right and left fascia bolts from the upper radiator crossmember (Figure 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7733 g. Pull the wheelhouse shield back from the front fascia and remove the right and left nuts holding the front fascia to the front lip of the fender (Figure 3). h. Carefully remove the front fascia and set it aside. CAUTION: Be careful not to scratch the painted surfaces of the front fascia and front fenders. i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard. j. Using a cut-off wheel, remove the head of the airbag sensor mounting bolt. k. Remove and discard the supplemental front airbag sensor bushing. l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool. NOTE: Be sure to completely remove the riv-nut from the lower radiator crossmember. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7734 n. Pre-assemble the new riv-nut by installing the installation nut and the riv-nut onto the installation bolt as shown in Figure 4. o. Insert the new riv-nut-bolt/nut assembly into the original riv-nut hole in the lower radiator crossmember. p. Using a 10mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5). q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut. r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely). 8. For vehicles that had the front fascia removed, use the following procedure to install the front fascia: a. Position the front fascia onto the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7735 b. Install the right and left upper fascia bolts finger tight (Figure 6). c. Install the right and left nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m). d. Install and tighten the two fascia-to-fender bolts. e. Install the four screws (two on each side) that secure the right and left wheelhouse shield to the front fascia. f. Using new push pins if necessary, install the air dam to the lower radiator crossmember. g. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps. h. Continue with Step 9. 9. Inspect the right and left supplemental front airbag sensor wiring connectors. > If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B. Airbag Sensor Harness Connector Replacement. > If there is no corrosion on either terminal of the harness connectors, continue with Section C. Supplemental Front Airbag Sensor Installation. B. Airbag Sensor Harness Connector(s) Replacement NOTE: Only those harness connector(s) that exhibit terminal corrosion, as described in Section A, require replacement. 1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector. 2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness. 3. Remove 1/2 inch (13 mm) of insulation from each wire. 4. Cut the new harness connector wires so that the final length is equal to the old harness. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7736 5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire. 6. Slide one piece of heat shrink tubing onto each of the harness connector wires. 7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just enough to hold the splice band in place. 8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows: > For the right (passenger side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the purple (w/blue tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the white (w/blue tracer) wire on the body wiring harness. > For the left (driver's side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the blue (w/purple tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the blue (w/white tracer) wire on the body wiring harness. CAUTION: Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band. 10. Crimp the splice band and wires together by squeezing the crimping tool handles. NOTE: The tool will release once the proper crimping force has been achieved. 11. Solder the connection together using only rosin core type solder. CAUTION: DO NOT use acid core solder. 12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing. CAUTION: Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure. 13. Continue with Section C. Supplemental Front Airbag Sensor Installation. C. Supplemental Front Airbag Sensor Installation 1. Clean the supplemental front airbag sensor mounting surface for both sensors. 2. Install the new supplemental front airbag sensors using the fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091. NOTE: Use the bolts with a blue thread locker patch on the threads. Discard the pointed self tapping screws and flat washers. They will not be used in this repair procedure. 3. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. 4. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7737 5. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector (Figure 7). NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor wiring harness connector. 6. Connect the wiring harness connectors to the right and left supplemental front airbag sensors. 7. Lower the vehicle from the hoist. 8. For vehicles that had the Fascia removed, tighten the upper fascia bolts to 50 in. lbs. (5 N.m). 9. Connect the negative battery cable to the battery. 10. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "RUN" position. Wait 10 seconds: > If the airbag warning light is not illuminated, the repair has been completed. No further action is required, return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 11 to clear the Diagnostic Trouble Codes (DTC's). 11. Use the following procedure to clear DTC's: a. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. b. Turn the ignition key to the "RUN" position. c. Press the "YES" button after the DRBIII powers up. d. Select "DRBIII STANDALONE" and press "ENTER". e. Select "1998-2007 DIAGNOSTICS" and press "ENTER". f. Select "ALL" and press "ENTER". g. Select "PASSIVE RESTRAINT" and press "ENTER". h. Select "AIRBAG" and press "ENTER". i. Select "READ DTC's" and press "ENTER". j. Select "STORED" and press "ENTER". k. Press the "PAGE BACK" button and follow the screen prompts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7738 l. Disconnect and remove the DRBIII from the vehicle and return the vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement Technical Service Bulletin # G09 Date: 070601 Recall - Front Air Bag Impact Sensor Replacement June 2007 Dealer Service Instructions for: Customer Satisfaction Notification G09 Supplemental Front Airbag Sensors Models 2005 (RS) Dodge Caravan, Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles built at the Windsor Assembly plant ("R" in the 11th VIN position) through February 3, 2005 (MDH 020323) and the St. Louis Assembly plant ("B" in the 11th VIN position) through January 19, 2005 (MDH 011923). IMPORTANT: Many of the vehicles within the above build period have already been repaired according to our warranty records, and therefore, have been excluded from this notification. Only the above vehicles originally sold or currently registered in certain states are involved. See the "Owner Notification and Service Scheduling" section for a list of states involved in this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair service on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The supplemental front airbag sensors on about 263,000 of the above vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Repair The right and left supplemental front airbag sensors must be replaced and the sensor harness connectors must be inspected and replaced, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7743 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7744 Parts Information Special Tools The special tools may be required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record repair service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7745 Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Attached to each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Only vehicles originally sold or currently registered in the following states are involved in this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Supplemental Front Airbag Sensor Replacement 1. Lower the driver¡C■s window completely. 2. Open the hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7746 3. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Raise the vehicle on a suitable hoist. 5. Disconnect the harness connector to the right and left supplemental front airbag sensor (Figure 1). 6. Remove the right and left supplemental front airbag sensors and discard the bolts and sensors. NOTE: There are two types of bolts used to fasten the sensors to the radiator crossmember; an M7 self tapping bolt or an M6 bolt used with a riv-nut. If the bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensors, continue with Step 8. 7. Replaced a spun riv-nut as follows: NOTE: The following procedure is applicable for vehicle built at the Windsor Assembly Plant after May 24, 2004 or the St. Louis Assembly Plant after June 28, 2004. Very few vehicles are expected to require riv-nut replacement. a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps. b. Remove the two screws that secure the left and right wheelhouse splash shield to the front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7747 c Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. d. Partially lower the vehicle. e. Remove the right and left fascia upper bolts from the upper radiator crossmember (Figure 2). f. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Figure 3) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7748 g. Remove the two vertical screws holding the front fascia to the front fender. h. Carefully remove the front fascia and set it aside. CAUTION: Be careful not to scratch the painted surfaces of the front fascia and the front fenders. i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard. j. Using a cut-off wheel, cut off the head of the airbag sensor mounting bolt. k. Remove and discard the supplemental front airbag sensor bushing. l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool. NOTE: Be sure to completely remove the riv-nut from the lower radiator crossmember. n. Pre-assemble the new riv-nut by installing the M6 nut and the riv-nut onto the M6 bolt as shown in Figure 4. o. Insert the riv-nut-bolt/nut assembly into the body sheet metal hole. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7749 p. Using a 10 mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5). q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut. r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely). s. Clean the supplemental front airbag sensor mounting surface for both sensors. t. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091: > For sensors fastened with self tapping bolts: a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6. b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts. c. Tightening the self tapping bolts to 60 in.lbs. (7 N.m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7750 > For sensors fastened with M6 bolts and riv-nuts: a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). u. Inspect the right and left supplemental front airbag sensor wiring connectors. If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B Harness Connector Replacement. v. Position the front fascia onto the vehicle. w. Install the right and left upper bolts fascia bolts and tighten to 50 in. lbs. (5 N.m). x. Install the right and left horizontal nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m). y. Install and tighten the two vertical screws that secure the front fascia to the front fenders. z. Install the two screws that secure the right and left wheelhouse shield to the front fascia. aa. Using new push pins if necessary, install the air dam to the lower radiator crossmember. ab. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps. ac. Continue with Step 10. 8. Clean the supplemental front airbag sensor mounting surface for both sensors. 9. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091: > For sensors fastened with self tapping bolts: a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6. b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts. c. Tightening the self tapping bolts to 60 in. lbs. (7 N.m). > For sensors fastened with M6 bolts and riv-nuts: a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). 10. Inspect the right and left supplemental front airbag sensor wiring connectors. If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B - Harness Connector Replacement. 11. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector. NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector. 12. Connect harness connectors to the right and left supplemental front airbag sensors. 13. Lower the vehicle. 14. Connect the negative battery cable to the battery. 15. Stand next to the vehicle with the driver¡C■s door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "ON" position. Wait 10 seconds: > If the airbag warning light is not illuminated the repair has been completed. Return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7751 continue with Step 16 to clear the sensor DTC. 16. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. 17. Turn the ignition key to the "ON" position. 18. Press the "YES" button when the DRBIII powers up. 19. Select "DRBIII STANDALONE" and press "ENTER". 20. Select "1997-2007 DIAGNOSTICS" and press "ENTER". 21. Select "ALL" and press "ENTER" 22. Select "PASSIVE RESTRAINT" and press "ENTER". 23. Select "CLEAR DTCS". 24. Disconnect and remove the DRBIII from the vehicle. B. Airbag Sensor Harness Connector Replacement NOTE: Only those harness connectors that exhibit terminal corrosion, as described in Section A, require replacement. 1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector. 2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness. 3. Remove 1/2 inch (13 mm) of insulation from each wire. 4. Cut the new harness connector wires so that the final length is equal to the old harness. 5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire. 6. Slide one piece of heat shrink tubing onto each of the harness connector wires. 7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just the tool just CAUTION: The crimp jaw must be installed in the crimp tool frame as shown in Figure 7. The crimp jaw wire gauge numbers must be on the same side. When installing the crimp jaw into the tool frame, orient the upper die with the arrow pointed "up" and the lower die with the arrow pointed forward. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7752 8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows: > For the right (passenger side) supplemental front airbag sensor, match the new harness connector wire colors to the same color wire on the existing body wire harness. > For the left (driver's side) supplemental front airbag sensor, match the new harness connector wire colors to same tracer (stripe) color wire on the existing body wire harness. CAUTION: Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. warning lamp. 9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band (Figure 8). 10. Crimp the splice band and wires together by squeezing the crimping tool handles. The tool will release once the proper crimping force has been achieved (Figure 8). 11. Solder the connection together using only rosin-core type solder (Figure. 9). CAUTION: DO NOT use acid core solder. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7753 12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Figure 10). CAUTION: Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure. 13. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector. NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector. 14. Connect harness connectors to the right and left supplemental front airbag sensors. 15. For vehicles with the front fascia removed: a. Position the front fascia onto the vehicle. b. Install the right and left upper fascia bolts and tighten to 50 in. lbs. (5 N.m). c. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender. Tighten the nuts to 60 in. lbs. (7 N.m). d. Install and tighten the two vertical screws that secure the front fascia to the front fenders. e. Install the two screws that secure the right and left wheelhouse shield to the front fascia. f. Using new push pins if necessary, securing the air dam to the lower radiator crossmember. g. For vehicles with fog lamps, connect the electrical harness connectors to the right and left fog lamps. 16. Lower the vehicle. 17. Connect the negative battery cable to the battery. 18. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel, and turn the ignition key to the "ON" position. Wait 10 seconds: > If the airbag warning light is not illuminated, the repair has been completed. Return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 19 to clear the sensor DTC. 19. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. 20. Turn the ignition key to the "ON" position. 21. Press the "YES" button when the DRBIII powers up. 22. Select "DRBIII STANDALONE" and press "ENTER". 23. Select "1997-2007 DIAGNOSTICS" and press "ENTER". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7754 24. Select "ALL" and press "ENTER". 25. Select "PASSIVE RESTRAINT" and press "ENTER". 26. Select "CLEAR DTCS". 27. Disconnect and remove the DRBIII from the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > NHTSA07V192000 > May > 07 > Recall 07V191000: Air Bag Impact Sensor Replacement Impact Sensor: Recalls Recall 07V191000: Air Bag Impact Sensor Replacement MAKE/MODELS: MODEL/BUILD YEARS: Chrysler/Town & Country 2005 Dodge/Caravan 2005 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V192000 MFR'S REPORT DATE: May 01, 2007 COMPONENT: Air Bags: Frontal: Sensor/Control Module POTENTIAL NUMBER OF UNITS AFFECTED: 270958 SUMMARY: Certain minivans are being recalled that were originally sold in or currently registered in the 27 states plus The District of Columbia that use greater amounts of salt for Winter road deicing. The Up-Front (UF) air bag sensors that contain brass bushings installed in these vehicles may corrode and crack allowing water to enter the sensor. These sensors provide enhanced air bag performance in certain types of frontal crashes. CONSEQUENCE: In one of these crashes, with one or both of the vehicle the vehicle's UF sensors inoperative, the occupants will not benefit from the enhanced air bag protection that these sensors would provide. REMEDY: For vehicles registered in the recall states, dealers will replace the original UF air bag sensors with ones with greater corrosion resistance. Vehicles registered in other states will obtain a lifetime free replacement of any UF sensor that fails. The campaign is expected to begin during July 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler's campaign Nos. G09/X16. DaimlerChrysler has not decided that this is a defect related to motor vehicle safety. However, it has informed NHTSA that it will provide the modifications described above free of charge. Customers also may contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline aT 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set Technical Service Bulletin # 08-020-07 Date: 070713 Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set NUMBER: 08-020-07 GROUP: Electrical DATE: July 13, 2007 SUBJECT: Supplemental Front Air Bag Sensor Replacement (Lifetime Warranty) OVERVIEW: This bulletin involves verifying that a right and/or left front impact supplemental airbag sensor(s) Diagnostic Trouble Code (DTC) exists in the Occupant Restraint Control Module (ORG). If DTC's exist, the right and left supplemental front airbag sensors must be replaced and the sensor harness connectors must be inspected for corrosion and replaced if necessary. NOTE: Technicians performing this procedure for the first time should fully familiarize themselves with the steps and procedures listed in this Service Bulletin before proceeding. MODELS: 2005 (RG) Chrysler Voyager 2005 (RS) Town & Country/Caravan/Voyager NOTE: This bulletin applies to vehicles built at the Windsor Assembly Plant ("R" in the 11th VIN position) through February 3, 2005 (MDH 020323), the St. Louis Assembly plant ("B" in the 11th VIN position) through January 19, 2005 (MDH 011923) or the Styler Assembly plant ("Y" in the 11th VIN position) through January 04, 2005 (MDH 010423). DISCUSSION: The supplemental front airbag sensors may crack under certain conditions and allow water to enter into the sensor(s). These sensors were added to enhance the performance of the vehicles airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. DIAGNOSIS: If the vehicle operator experiences air bag warning lamp illumination with any of the following DTC's; NO RIGHT FRONT IMPACT SENSOR COMMUNICATION / RIGHT FRONT IMPACT SENSOR INTERNAL 1/ NO LEFT FRONT IMPACT SENSOR COMMUNICATION or LEFT FRONT IMPACT SENSOR INTERNAL 1, perform the Repair Procedure. If the air bag warning lamp is on due to other DTC's, this bulletin does not apply. Refer to diagnostic procedures available in DealerCONNECT >>> TechCONNECT under: Diagnostics > 7.2 AIRBAG for further information. NOTE: Vehicles that are included in Customer Satisfaction Notification G09 are not included in this Service Bulletin and must be repaired under the procedures and labor operation numbers listed within G09. Vehicles not included in G09 must use this Service Bulletin for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7764 PARTS REQUIRED: NOTE: Connectors, Self-Tapping Screws and Riv-nuts will be used on an "as needed" basis. SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. NOTE: Vehicles included in this Service Bulletin have a lifetime warranty on supplemental front airbag sensors, mounting hardware and sensor electrical connectors as described in this Service Bulletin. See Warranty Bulletin D-07-19 for details associated with the lifetime warranty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7765 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Lower the driver's side window. 2. Disconnect the Negative Battery Cable. 3. Refer to the detailed removal procedures available in DealerCONNECT >>> TechCONNECT under: Service Information Tab >>> Group 8, Electrical >>> Restraints >>> Impact Sensor >>> Removal. 4. When removing the attaching bolts for the sensor, does any of the bolts spin freely and not come out? (See NOTES below). a. Yes >>> Proceed to Step # 5 b. No >>> Proceed to Step # 22 NOTE: There are 2 types of bolts used to fasten the sensors to the radiator crossmember; a M7 self tapping bolt or a M6 bolt used with a riv-nut. If the bolt spins and cannot be removed, the riv-nut has broken loose. If the riv-nut spins and the bolt cannot be removed, proceed to next step to replace riv-nut(s). If no issue with the riv-nut is found, proceed to Step # 22. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7766 NOTE: The riv-nut procedure is applicable for vehicles built at the Windsor Assembly plant after May 24, 2004 or the St. Louis Assembly plant after June 28, 2004 or the Styler Assembly plant after June 28, 2004. Very few vehicles will require riv-nut replacement. 5. If the vehicle equipped with fog lamps, disconnect electrical harness connectors from both fog lamps. 6. Remove the 2 screws that secure the left and right wheelhouse splash shield to the front fascia. 7. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. 8. Remove the right and left fascia upper bolts from the upper radiator crossmember. (Fig 2) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7767 9. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Fig. 3) 10. Remove 2 vertical screws holding the front fascia to the front fender. 11. Carefully remove the front fascia and set aside. CAUTION: Care should be used not to damage painted surfaces. 12. Break the front air bag sensor using a suitable tool. Remove broken sensor pieces. 13. Using a powered cut-off wheel, remove the head of the sensor mounting bolt. 14. Remove sensor bushing from bolt. 15. Using a powered cut-off wheel, cut the bolt and lip of the riv-nut flush with sheet metal. 16. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. 17. Remove the old riv-nut through the access hole in the crossmember using a magnetic tool. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7768 18. Preassemble the new riv-nut, p/n CBX2G093 by installing the M6 nut, and the riv-nut onto the bolt, as shown in (Fig. 4). 19. Insert the riv-nut and bolt assembly into the original mounting hole. 20. Using a 10 mm crows foot, tighten the installation nut to 9 Nm, (80 in. lb) while holding the installation bolt stationary (Fig. 5). 21. Repeat Step # 12 through Step # 20 for remaining riv-nut(s) that have broken loose and spin freely. 22. Clean the mounting surface for both sensors. 23. Install the new sensors using the appropriate fasteners; Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7769 a. For sensors fastened with self-tapping bolts. Proceed to >>> # 24. b. For sensors fastened with M6 bolts and riv-nuts. Proceed to >>> Step # 26. 24. For self-tapping fastener installation; preassemble both air bag sensors with self-tapping bolts and washers (Fig. 6). 25. Position the sensors on the vehicle and tighten each self-tapping bolt into the mounting hole about 5 turns to cut new threads for the larger M7 bolt. Tighten to 7 Nm, (60 in. lb). Proceed to Step # 27. 26. For M6 bolt and riv-nut fastener installation; hand start both bolts in sensors. Tighten to 7 Nm, (60 in. lb). 27. Inspect the right and left air bag sensor wiring connectors. Is there is any sign of corrosion, (white, green or black), on either terminal of the harness connectors? a. Yes >>> Proceed to Step # 28. b. No >>> Proceed to Step # 39. NOTE: Only replace harness connectors that exhibit terminal corrosion. 28. Cut wire harness 3 in. (75 mm) back from connector. 29. Remove 1 in. (25 mm) of black tape from wire harness going to the vehicle. 30. Strip .5 in. (13 mm) of insulation from each wire. 31. Cut the new sensor connector wire harness p/n CBX2G092 the same length as the removed connector wire harness. 32. Strip .5 in. (13 mm) of insulation from each wire. 33. Slide one piece of heat shrink tubing on each of the wires. 34. Load and center the splice band into cavity "B" of crimp tool # 10042. Close the tool just enough to hold the splice band in place NOTE: First time use of crimp tool #10042 will require the crimp dies to be installed on the crimper frame. Orient the upper die with the arrow pointed up and the lower die with the arrow pointed forward. The numbers on upper die and letters on lower die will be on the same side. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7770 35. Match the new harness connector wires to the existing vehicle harness as follows: a. For the right (passenger side) sensor, match the new harness connector wire colors to the same color wire on the existing vehicle wire harness. b. For the left (driver side) sensor, match the new harness connector wire colors to the same tracer stripe color wire on the existing vehicle wire harness. CAUTION: Ensure wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 36. Insert the matched bare wires through the crimp connector from opposite ends. Crimp the connections using #10042 wire splice crimp tool. 37. Solder the crimped connection using only rosin-core solder. 38. Center heat shrink tubing over the connection and heat with a heat gun until tubing is tight and sealant is witnessed at the ends (Fig 7). CAUTION: Use only the sealant lined heat shrink tube supplied in wiring kit above. Use of electrical tape or non-sealant lined heat shrink tube may cause circuit failure. 39. Apply a small amount of dielectric grease, p/n J81 26688 to the airbag sensor connector end. Using a finger, force the grease into the terminal connections of the airbag sensor connector. 40. Connect the harness connectors to both front airbag sensors. 41. Has the fascia been removed? a. Yes >>> Proceed to Step # 42. b. No >>> Proceed to Step # 49. 42. Position the front fascia onto the vehicle. 43. Install the right and left upper fascia bolts, tighten to 5 Nm (50 in lb). 44. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender and tighten to 7 Nm (60 in lb). 45. Install the two vertical screws that secure the front fascia to the front fenders. 46. Install the two screws that secure the right and left wheelhouse shield to the front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7771 47. Using new push pins, if necessary, securing the air dam to the lower radiator crossmember. 48. Connect the electrical harness connectors to the right and left fog lamps, if equipped. 49. Connect the negative battery cable to the battery. 50. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel, and turn the ignition key to the "ON position. Wait 10 seconds: a. If the airbag warning light is not illuminated, the repair is complete. Proceed to to clear stored DTC's. b. If the airbag warning light is illuminated due to supplemental front airbag sensor faults, switch the ignition key "OFF and Proceed to and clear any DTC's. If the DTC's return and ARE related to the Front Impact Sensor(s), Verify proper wiring connections as described in above. If wiring connections are correct, or if DTC's are related to other components of the supplemental airbag system, refer to the diagnostic information available in DealerCONNECT >>> TechCONNECT under: Diagnostics > 7.2 AIRBAG for further information. 51. Turn the ignition "OFF" and connect the DRBIII(R). NOTE: The DRBIII(R) must be at software Version 64.0 or later. 52. Turn the ignition key to "ON". 53. Press the "YES" button when the DRBIII(R) powers up. 54. Select "DRBIII(R) STANDALONE" and press "ENTER". 55. Select "1997-2007 DIAGNOSTICS" and press "ENTER". 56. Select "ALL" and press "ENTER". 57. Select "PASSIVE RESTRAINT" and press "ENTER". 58. Select "CLEAR DTCS". 59. Disconnect and remove the DRBIII(R) from the vehicle. 60. Reset clock. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement Technical Service Bulletin # J38 Date: 100420 Campaign - Front Air Bag Sensor Replacement April 2010 Dealer Service Instructions for: Customer Satisfaction Notification J38 Supplemental Front Airbag Sensors Models 2005-2006 (RS) Dodge Caravan, Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles built from January 19, 2005 through April 5, 2006 (MDH 011900 through 040500). IMPORTANT: Many of the vehicles within the above build period have already been repaired according to our warranty records, and therefore, have been excluded from this notification. Only the above vehicles originally sold or currently registered in certain states are involved. See the "Owner Notification and Service Scheduling" section for a list of states involved in this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The supplemental front airbag sensors on about 310,000 of the above vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Repair The right and left supplemental front airbag sensors must be replaced and the sensor wiring harness connectors must be inspected and replaced, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7777 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7778 Parts Information Special Tools The following special tools may be required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7779 Use the labor operation numbers and time allowances as shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicableable. Only vehicles originally sold or currently registered in the following states are involved in this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7780 To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure A. Supplemental Front Airbag Sensor Replacement 1. Lower the driver's window completely. 2. Open the hood. 3. Disconnect and isolate the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Raise the vehicle on a suitable hoist. 5. Disconnect the wiring harness connector to the right and left supplemental front airbag sensor. The sensors are located on the outside of the right and left frame rails at the radiator lower crossmember (Figure 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7781 6. Remove the right and left supplemental front airbag sensors and discard the sensors and retaining bolts. CAUTION: If the retaining bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose from the radiator lower crossmember. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensor retaining bolts, continue with Step 9. 7. Use the following procedure, if required, to replace a spun riv-nut: a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps. b. Remove the four screws (two each side) that secure the left and right wheelhouse splash shield to the front fascia. c. Remove the right and left side fascia-to-fender bolts. d. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. e. Partially lower the vehicle. f. Remove the right and left fascia bolts from the upper radiator crossmember (Figure 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7782 g. Pull the wheelhouse shield back from the front fascia and remove the right and left nuts holding the front fascia to the front lip of the fender (Figure 3). h. Carefully remove the front fascia and set it aside. CAUTION: Be careful not to scratch the painted surfaces of the front fascia and front fenders. i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard. j. Using a cut-off wheel, remove the head of the airbag sensor mounting bolt. k. Remove and discard the supplemental front airbag sensor bushing. l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool. NOTE: Be sure to completely remove the riv-nut from the lower radiator crossmember. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7783 n. Pre-assemble the new riv-nut by installing the installation nut and the riv-nut onto the installation bolt as shown in Figure 4. o. Insert the new riv-nut-bolt/nut assembly into the original riv-nut hole in the lower radiator crossmember. p. Using a 10mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5). q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut. r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely). 8. For vehicles that had the front fascia removed, use the following procedure to install the front fascia: a. Position the front fascia onto the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7784 b. Install the right and left upper fascia bolts finger tight (Figure 6). c. Install the right and left nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m). d. Install and tighten the two fascia-to-fender bolts. e. Install the four screws (two on each side) that secure the right and left wheelhouse shield to the front fascia. f. Using new push pins if necessary, install the air dam to the lower radiator crossmember. g. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps. h. Continue with Step 9. 9. Inspect the right and left supplemental front airbag sensor wiring connectors. > If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B. Airbag Sensor Harness Connector Replacement. > If there is no corrosion on either terminal of the harness connectors, continue with Section C. Supplemental Front Airbag Sensor Installation. B. Airbag Sensor Harness Connector(s) Replacement NOTE: Only those harness connector(s) that exhibit terminal corrosion, as described in Section A, require replacement. 1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector. 2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness. 3. Remove 1/2 inch (13 mm) of insulation from each wire. 4. Cut the new harness connector wires so that the final length is equal to the old harness. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7785 5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire. 6. Slide one piece of heat shrink tubing onto each of the harness connector wires. 7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just enough to hold the splice band in place. 8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows: > For the right (passenger side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the purple (w/blue tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the white (w/blue tracer) wire on the body wiring harness. > For the left (driver's side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the blue (w/purple tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the blue (w/white tracer) wire on the body wiring harness. CAUTION: Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band. 10. Crimp the splice band and wires together by squeezing the crimping tool handles. NOTE: The tool will release once the proper crimping force has been achieved. 11. Solder the connection together using only rosin core type solder. CAUTION: DO NOT use acid core solder. 12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing. CAUTION: Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure. 13. Continue with Section C. Supplemental Front Airbag Sensor Installation. C. Supplemental Front Airbag Sensor Installation 1. Clean the supplemental front airbag sensor mounting surface for both sensors. 2. Install the new supplemental front airbag sensors using the fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091. NOTE: Use the bolts with a blue thread locker patch on the threads. Discard the pointed self tapping screws and flat washers. They will not be used in this repair procedure. 3. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. 4. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7786 5. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector (Figure 7). NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor wiring harness connector. 6. Connect the wiring harness connectors to the right and left supplemental front airbag sensors. 7. Lower the vehicle from the hoist. 8. For vehicles that had the Fascia removed, tighten the upper fascia bolts to 50 in. lbs. (5 N.m). 9. Connect the negative battery cable to the battery. 10. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "RUN" position. Wait 10 seconds: > If the airbag warning light is not illuminated, the repair has been completed. No further action is required, return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 11 to clear the Diagnostic Trouble Codes (DTC's). 11. Use the following procedure to clear DTC's: a. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. b. Turn the ignition key to the "RUN" position. c. Press the "YES" button after the DRBIII powers up. d. Select "DRBIII STANDALONE" and press "ENTER". e. Select "1998-2007 DIAGNOSTICS" and press "ENTER". f. Select "ALL" and press "ENTER". g. Select "PASSIVE RESTRAINT" and press "ENTER". h. Select "AIRBAG" and press "ENTER". i. Select "READ DTC's" and press "ENTER". j. Select "STORED" and press "ENTER". k. Press the "PAGE BACK" button and follow the screen prompts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7787 l. Disconnect and remove the DRBIII from the vehicle and return the vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set Technical Service Bulletin # 08-020-07 Date: 070713 Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set NUMBER: 08-020-07 GROUP: Electrical DATE: July 13, 2007 SUBJECT: Supplemental Front Air Bag Sensor Replacement (Lifetime Warranty) OVERVIEW: This bulletin involves verifying that a right and/or left front impact supplemental airbag sensor(s) Diagnostic Trouble Code (DTC) exists in the Occupant Restraint Control Module (ORG). If DTC's exist, the right and left supplemental front airbag sensors must be replaced and the sensor harness connectors must be inspected for corrosion and replaced if necessary. NOTE: Technicians performing this procedure for the first time should fully familiarize themselves with the steps and procedures listed in this Service Bulletin before proceeding. MODELS: 2005 (RG) Chrysler Voyager 2005 (RS) Town & Country/Caravan/Voyager NOTE: This bulletin applies to vehicles built at the Windsor Assembly Plant ("R" in the 11th VIN position) through February 3, 2005 (MDH 020323), the St. Louis Assembly plant ("B" in the 11th VIN position) through January 19, 2005 (MDH 011923) or the Styler Assembly plant ("Y" in the 11th VIN position) through January 04, 2005 (MDH 010423). DISCUSSION: The supplemental front airbag sensors may crack under certain conditions and allow water to enter into the sensor(s). These sensors were added to enhance the performance of the vehicles airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. DIAGNOSIS: If the vehicle operator experiences air bag warning lamp illumination with any of the following DTC's; NO RIGHT FRONT IMPACT SENSOR COMMUNICATION / RIGHT FRONT IMPACT SENSOR INTERNAL 1/ NO LEFT FRONT IMPACT SENSOR COMMUNICATION or LEFT FRONT IMPACT SENSOR INTERNAL 1, perform the Repair Procedure. If the air bag warning lamp is on due to other DTC's, this bulletin does not apply. Refer to diagnostic procedures available in DealerCONNECT >>> TechCONNECT under: Diagnostics > 7.2 AIRBAG for further information. NOTE: Vehicles that are included in Customer Satisfaction Notification G09 are not included in this Service Bulletin and must be repaired under the procedures and labor operation numbers listed within G09. Vehicles not included in G09 must use this Service Bulletin for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7792 PARTS REQUIRED: NOTE: Connectors, Self-Tapping Screws and Riv-nuts will be used on an "as needed" basis. SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. NOTE: Vehicles included in this Service Bulletin have a lifetime warranty on supplemental front airbag sensors, mounting hardware and sensor electrical connectors as described in this Service Bulletin. See Warranty Bulletin D-07-19 for details associated with the lifetime warranty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7793 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Lower the driver's side window. 2. Disconnect the Negative Battery Cable. 3. Refer to the detailed removal procedures available in DealerCONNECT >>> TechCONNECT under: Service Information Tab >>> Group 8, Electrical >>> Restraints >>> Impact Sensor >>> Removal. 4. When removing the attaching bolts for the sensor, does any of the bolts spin freely and not come out? (See NOTES below). a. Yes >>> Proceed to Step # 5 b. No >>> Proceed to Step # 22 NOTE: There are 2 types of bolts used to fasten the sensors to the radiator crossmember; a M7 self tapping bolt or a M6 bolt used with a riv-nut. If the bolt spins and cannot be removed, the riv-nut has broken loose. If the riv-nut spins and the bolt cannot be removed, proceed to next step to replace riv-nut(s). If no issue with the riv-nut is found, proceed to Step # 22. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7794 NOTE: The riv-nut procedure is applicable for vehicles built at the Windsor Assembly plant after May 24, 2004 or the St. Louis Assembly plant after June 28, 2004 or the Styler Assembly plant after June 28, 2004. Very few vehicles will require riv-nut replacement. 5. If the vehicle equipped with fog lamps, disconnect electrical harness connectors from both fog lamps. 6. Remove the 2 screws that secure the left and right wheelhouse splash shield to the front fascia. 7. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. 8. Remove the right and left fascia upper bolts from the upper radiator crossmember. (Fig 2) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7795 9. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Fig. 3) 10. Remove 2 vertical screws holding the front fascia to the front fender. 11. Carefully remove the front fascia and set aside. CAUTION: Care should be used not to damage painted surfaces. 12. Break the front air bag sensor using a suitable tool. Remove broken sensor pieces. 13. Using a powered cut-off wheel, remove the head of the sensor mounting bolt. 14. Remove sensor bushing from bolt. 15. Using a powered cut-off wheel, cut the bolt and lip of the riv-nut flush with sheet metal. 16. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. 17. Remove the old riv-nut through the access hole in the crossmember using a magnetic tool. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7796 18. Preassemble the new riv-nut, p/n CBX2G093 by installing the M6 nut, and the riv-nut onto the bolt, as shown in (Fig. 4). 19. Insert the riv-nut and bolt assembly into the original mounting hole. 20. Using a 10 mm crows foot, tighten the installation nut to 9 Nm, (80 in. lb) while holding the installation bolt stationary (Fig. 5). 21. Repeat Step # 12 through Step # 20 for remaining riv-nut(s) that have broken loose and spin freely. 22. Clean the mounting surface for both sensors. 23. Install the new sensors using the appropriate fasteners; Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7797 a. For sensors fastened with self-tapping bolts. Proceed to >>> # 24. b. For sensors fastened with M6 bolts and riv-nuts. Proceed to >>> Step # 26. 24. For self-tapping fastener installation; preassemble both air bag sensors with self-tapping bolts and washers (Fig. 6). 25. Position the sensors on the vehicle and tighten each self-tapping bolt into the mounting hole about 5 turns to cut new threads for the larger M7 bolt. Tighten to 7 Nm, (60 in. lb). Proceed to Step # 27. 26. For M6 bolt and riv-nut fastener installation; hand start both bolts in sensors. Tighten to 7 Nm, (60 in. lb). 27. Inspect the right and left air bag sensor wiring connectors. Is there is any sign of corrosion, (white, green or black), on either terminal of the harness connectors? a. Yes >>> Proceed to Step # 28. b. No >>> Proceed to Step # 39. NOTE: Only replace harness connectors that exhibit terminal corrosion. 28. Cut wire harness 3 in. (75 mm) back from connector. 29. Remove 1 in. (25 mm) of black tape from wire harness going to the vehicle. 30. Strip .5 in. (13 mm) of insulation from each wire. 31. Cut the new sensor connector wire harness p/n CBX2G092 the same length as the removed connector wire harness. 32. Strip .5 in. (13 mm) of insulation from each wire. 33. Slide one piece of heat shrink tubing on each of the wires. 34. Load and center the splice band into cavity "B" of crimp tool # 10042. Close the tool just enough to hold the splice band in place NOTE: First time use of crimp tool #10042 will require the crimp dies to be installed on the crimper frame. Orient the upper die with the arrow pointed up and the lower die with the arrow pointed forward. The numbers on upper die and letters on lower die will be on the same side. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7798 35. Match the new harness connector wires to the existing vehicle harness as follows: a. For the right (passenger side) sensor, match the new harness connector wire colors to the same color wire on the existing vehicle wire harness. b. For the left (driver side) sensor, match the new harness connector wire colors to the same tracer stripe color wire on the existing vehicle wire harness. CAUTION: Ensure wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 36. Insert the matched bare wires through the crimp connector from opposite ends. Crimp the connections using #10042 wire splice crimp tool. 37. Solder the crimped connection using only rosin-core solder. 38. Center heat shrink tubing over the connection and heat with a heat gun until tubing is tight and sealant is witnessed at the ends (Fig 7). CAUTION: Use only the sealant lined heat shrink tube supplied in wiring kit above. Use of electrical tape or non-sealant lined heat shrink tube may cause circuit failure. 39. Apply a small amount of dielectric grease, p/n J81 26688 to the airbag sensor connector end. Using a finger, force the grease into the terminal connections of the airbag sensor connector. 40. Connect the harness connectors to both front airbag sensors. 41. Has the fascia been removed? a. Yes >>> Proceed to Step # 42. b. No >>> Proceed to Step # 49. 42. Position the front fascia onto the vehicle. 43. Install the right and left upper fascia bolts, tighten to 5 Nm (50 in lb). 44. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender and tighten to 7 Nm (60 in lb). 45. Install the two vertical screws that secure the front fascia to the front fenders. 46. Install the two screws that secure the right and left wheelhouse shield to the front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7799 47. Using new push pins, if necessary, securing the air dam to the lower radiator crossmember. 48. Connect the electrical harness connectors to the right and left fog lamps, if equipped. 49. Connect the negative battery cable to the battery. 50. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel, and turn the ignition key to the "ON position. Wait 10 seconds: a. If the airbag warning light is not illuminated, the repair is complete. Proceed to to clear stored DTC's. b. If the airbag warning light is illuminated due to supplemental front airbag sensor faults, switch the ignition key "OFF and Proceed to and clear any DTC's. If the DTC's return and ARE related to the Front Impact Sensor(s), Verify proper wiring connections as described in above. If wiring connections are correct, or if DTC's are related to other components of the supplemental airbag system, refer to the diagnostic information available in DealerCONNECT >>> TechCONNECT under: Diagnostics > 7.2 AIRBAG for further information. 51. Turn the ignition "OFF" and connect the DRBIII(R). NOTE: The DRBIII(R) must be at software Version 64.0 or later. 52. Turn the ignition key to "ON". 53. Press the "YES" button when the DRBIII(R) powers up. 54. Select "DRBIII(R) STANDALONE" and press "ENTER". 55. Select "1997-2007 DIAGNOSTICS" and press "ENTER". 56. Select "ALL" and press "ENTER". 57. Select "PASSIVE RESTRAINT" and press "ENTER". 58. Select "CLEAR DTCS". 59. Disconnect and remove the DRBIII(R) from the vehicle. 60. Reset clock. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement Technical Service Bulletin # G09 Date: 070601 Recall - Front Air Bag Impact Sensor Replacement June 2007 Dealer Service Instructions for: Customer Satisfaction Notification G09 Supplemental Front Airbag Sensors Models 2005 (RS) Dodge Caravan, Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles built at the Windsor Assembly plant ("R" in the 11th VIN position) through February 3, 2005 (MDH 020323) and the St. Louis Assembly plant ("B" in the 11th VIN position) through January 19, 2005 (MDH 011923). IMPORTANT: Many of the vehicles within the above build period have already been repaired according to our warranty records, and therefore, have been excluded from this notification. Only the above vehicles originally sold or currently registered in certain states are involved. See the "Owner Notification and Service Scheduling" section for a list of states involved in this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair service on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The supplemental front airbag sensors on about 263,000 of the above vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Repair The right and left supplemental front airbag sensors must be replaced and the sensor harness connectors must be inspected and replaced, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7804 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7805 Parts Information Special Tools The special tools may be required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record repair service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7806 Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Attached to each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Only vehicles originally sold or currently registered in the following states are involved in this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Supplemental Front Airbag Sensor Replacement 1. Lower the driver¡C■s window completely. 2. Open the hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7807 3. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Raise the vehicle on a suitable hoist. 5. Disconnect the harness connector to the right and left supplemental front airbag sensor (Figure 1). 6. Remove the right and left supplemental front airbag sensors and discard the bolts and sensors. NOTE: There are two types of bolts used to fasten the sensors to the radiator crossmember; an M7 self tapping bolt or an M6 bolt used with a riv-nut. If the bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensors, continue with Step 8. 7. Replaced a spun riv-nut as follows: NOTE: The following procedure is applicable for vehicle built at the Windsor Assembly Plant after May 24, 2004 or the St. Louis Assembly Plant after June 28, 2004. Very few vehicles are expected to require riv-nut replacement. a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps. b. Remove the two screws that secure the left and right wheelhouse splash shield to the front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7808 c Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. d. Partially lower the vehicle. e. Remove the right and left fascia upper bolts from the upper radiator crossmember (Figure 2). f. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Figure 3) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7809 g. Remove the two vertical screws holding the front fascia to the front fender. h. Carefully remove the front fascia and set it aside. CAUTION: Be careful not to scratch the painted surfaces of the front fascia and the front fenders. i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard. j. Using a cut-off wheel, cut off the head of the airbag sensor mounting bolt. k. Remove and discard the supplemental front airbag sensor bushing. l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool. NOTE: Be sure to completely remove the riv-nut from the lower radiator crossmember. n. Pre-assemble the new riv-nut by installing the M6 nut and the riv-nut onto the M6 bolt as shown in Figure 4. o. Insert the riv-nut-bolt/nut assembly into the body sheet metal hole. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7810 p. Using a 10 mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5). q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut. r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely). s. Clean the supplemental front airbag sensor mounting surface for both sensors. t. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091: > For sensors fastened with self tapping bolts: a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6. b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts. c. Tightening the self tapping bolts to 60 in.lbs. (7 N.m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7811 > For sensors fastened with M6 bolts and riv-nuts: a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). u. Inspect the right and left supplemental front airbag sensor wiring connectors. If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B Harness Connector Replacement. v. Position the front fascia onto the vehicle. w. Install the right and left upper bolts fascia bolts and tighten to 50 in. lbs. (5 N.m). x. Install the right and left horizontal nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m). y. Install and tighten the two vertical screws that secure the front fascia to the front fenders. z. Install the two screws that secure the right and left wheelhouse shield to the front fascia. aa. Using new push pins if necessary, install the air dam to the lower radiator crossmember. ab. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps. ac. Continue with Step 10. 8. Clean the supplemental front airbag sensor mounting surface for both sensors. 9. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091: > For sensors fastened with self tapping bolts: a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6. b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts. c. Tightening the self tapping bolts to 60 in. lbs. (7 N.m). > For sensors fastened with M6 bolts and riv-nuts: a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). 10. Inspect the right and left supplemental front airbag sensor wiring connectors. If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B - Harness Connector Replacement. 11. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector. NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector. 12. Connect harness connectors to the right and left supplemental front airbag sensors. 13. Lower the vehicle. 14. Connect the negative battery cable to the battery. 15. Stand next to the vehicle with the driver¡C■s door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "ON" position. Wait 10 seconds: > If the airbag warning light is not illuminated the repair has been completed. Return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7812 continue with Step 16 to clear the sensor DTC. 16. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. 17. Turn the ignition key to the "ON" position. 18. Press the "YES" button when the DRBIII powers up. 19. Select "DRBIII STANDALONE" and press "ENTER". 20. Select "1997-2007 DIAGNOSTICS" and press "ENTER". 21. Select "ALL" and press "ENTER" 22. Select "PASSIVE RESTRAINT" and press "ENTER". 23. Select "CLEAR DTCS". 24. Disconnect and remove the DRBIII from the vehicle. B. Airbag Sensor Harness Connector Replacement NOTE: Only those harness connectors that exhibit terminal corrosion, as described in Section A, require replacement. 1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector. 2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness. 3. Remove 1/2 inch (13 mm) of insulation from each wire. 4. Cut the new harness connector wires so that the final length is equal to the old harness. 5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire. 6. Slide one piece of heat shrink tubing onto each of the harness connector wires. 7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just the tool just CAUTION: The crimp jaw must be installed in the crimp tool frame as shown in Figure 7. The crimp jaw wire gauge numbers must be on the same side. When installing the crimp jaw into the tool frame, orient the upper die with the arrow pointed "up" and the lower die with the arrow pointed forward. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7813 8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows: > For the right (passenger side) supplemental front airbag sensor, match the new harness connector wire colors to the same color wire on the existing body wire harness. > For the left (driver's side) supplemental front airbag sensor, match the new harness connector wire colors to same tracer (stripe) color wire on the existing body wire harness. CAUTION: Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. warning lamp. 9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band (Figure 8). 10. Crimp the splice band and wires together by squeezing the crimping tool handles. The tool will release once the proper crimping force has been achieved (Figure 8). 11. Solder the connection together using only rosin-core type solder (Figure. 9). CAUTION: DO NOT use acid core solder. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7814 12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Figure 10). CAUTION: Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure. 13. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector. NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector. 14. Connect harness connectors to the right and left supplemental front airbag sensors. 15. For vehicles with the front fascia removed: a. Position the front fascia onto the vehicle. b. Install the right and left upper fascia bolts and tighten to 50 in. lbs. (5 N.m). c. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender. Tighten the nuts to 60 in. lbs. (7 N.m). d. Install and tighten the two vertical screws that secure the front fascia to the front fenders. e. Install the two screws that secure the right and left wheelhouse shield to the front fascia. f. Using new push pins if necessary, securing the air dam to the lower radiator crossmember. g. For vehicles with fog lamps, connect the electrical harness connectors to the right and left fog lamps. 16. Lower the vehicle. 17. Connect the negative battery cable to the battery. 18. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel, and turn the ignition key to the "ON" position. Wait 10 seconds: > If the airbag warning light is not illuminated, the repair has been completed. Return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 19 to clear the sensor DTC. 19. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. 20. Turn the ignition key to the "ON" position. 21. Press the "YES" button when the DRBIII powers up. 22. Select "DRBIII STANDALONE" and press "ENTER". 23. Select "1997-2007 DIAGNOSTICS" and press "ENTER". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7815 24. Select "ALL" and press "ENTER". 25. Select "PASSIVE RESTRAINT" and press "ENTER". 26. Select "CLEAR DTCS". 27. Disconnect and remove the DRBIII from the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > NHTSA07V192000 > May > 07 > Recall 07V191000: Air Bag Impact Sensor Replacement Impact Sensor: All Technical Service Bulletins Recall 07V191000: Air Bag Impact Sensor Replacement MAKE/MODELS: MODEL/BUILD YEARS: Chrysler/Town & Country 2005 Dodge/Caravan 2005 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V192000 MFR'S REPORT DATE: May 01, 2007 COMPONENT: Air Bags: Frontal: Sensor/Control Module POTENTIAL NUMBER OF UNITS AFFECTED: 270958 SUMMARY: Certain minivans are being recalled that were originally sold in or currently registered in the 27 states plus The District of Columbia that use greater amounts of salt for Winter road deicing. The Up-Front (UF) air bag sensors that contain brass bushings installed in these vehicles may corrode and crack allowing water to enter the sensor. These sensors provide enhanced air bag performance in certain types of frontal crashes. CONSEQUENCE: In one of these crashes, with one or both of the vehicle the vehicle's UF sensors inoperative, the occupants will not benefit from the enhanced air bag protection that these sensors would provide. REMEDY: For vehicles registered in the recall states, dealers will replace the original UF air bag sensors with ones with greater corrosion resistance. Vehicles registered in other states will obtain a lifetime free replacement of any UF sensor that fails. The campaign is expected to begin during July 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler's campaign Nos. G09/X16. DaimlerChrysler has not decided that this is a defect related to motor vehicle safety. However, it has informed NHTSA that it will provide the modifications described above free of charge. Customers also may contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline aT 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set Technical Service Bulletin # 08-020-07 Date: 070713 Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set NUMBER: 08-020-07 GROUP: Electrical DATE: July 13, 2007 SUBJECT: Supplemental Front Air Bag Sensor Replacement (Lifetime Warranty) OVERVIEW: This bulletin involves verifying that a right and/or left front impact supplemental airbag sensor(s) Diagnostic Trouble Code (DTC) exists in the Occupant Restraint Control Module (ORG). If DTC's exist, the right and left supplemental front airbag sensors must be replaced and the sensor harness connectors must be inspected for corrosion and replaced if necessary. NOTE: Technicians performing this procedure for the first time should fully familiarize themselves with the steps and procedures listed in this Service Bulletin before proceeding. MODELS: 2005 (RG) Chrysler Voyager 2005 (RS) Town & Country/Caravan/Voyager NOTE: This bulletin applies to vehicles built at the Windsor Assembly Plant ("R" in the 11th VIN position) through February 3, 2005 (MDH 020323), the St. Louis Assembly plant ("B" in the 11th VIN position) through January 19, 2005 (MDH 011923) or the Styler Assembly plant ("Y" in the 11th VIN position) through January 04, 2005 (MDH 010423). DISCUSSION: The supplemental front airbag sensors may crack under certain conditions and allow water to enter into the sensor(s). These sensors were added to enhance the performance of the vehicles airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. DIAGNOSIS: If the vehicle operator experiences air bag warning lamp illumination with any of the following DTC's; NO RIGHT FRONT IMPACT SENSOR COMMUNICATION / RIGHT FRONT IMPACT SENSOR INTERNAL 1/ NO LEFT FRONT IMPACT SENSOR COMMUNICATION or LEFT FRONT IMPACT SENSOR INTERNAL 1, perform the Repair Procedure. If the air bag warning lamp is on due to other DTC's, this bulletin does not apply. Refer to diagnostic procedures available in DealerCONNECT >>> TechCONNECT under: Diagnostics > 7.2 AIRBAG for further information. NOTE: Vehicles that are included in Customer Satisfaction Notification G09 are not included in this Service Bulletin and must be repaired under the procedures and labor operation numbers listed within G09. Vehicles not included in G09 must use this Service Bulletin for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7825 PARTS REQUIRED: NOTE: Connectors, Self-Tapping Screws and Riv-nuts will be used on an "as needed" basis. SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. NOTE: Vehicles included in this Service Bulletin have a lifetime warranty on supplemental front airbag sensors, mounting hardware and sensor electrical connectors as described in this Service Bulletin. See Warranty Bulletin D-07-19 for details associated with the lifetime warranty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7826 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Lower the driver's side window. 2. Disconnect the Negative Battery Cable. 3. Refer to the detailed removal procedures available in DealerCONNECT >>> TechCONNECT under: Service Information Tab >>> Group 8, Electrical >>> Restraints >>> Impact Sensor >>> Removal. 4. When removing the attaching bolts for the sensor, does any of the bolts spin freely and not come out? (See NOTES below). a. Yes >>> Proceed to Step # 5 b. No >>> Proceed to Step # 22 NOTE: There are 2 types of bolts used to fasten the sensors to the radiator crossmember; a M7 self tapping bolt or a M6 bolt used with a riv-nut. If the bolt spins and cannot be removed, the riv-nut has broken loose. If the riv-nut spins and the bolt cannot be removed, proceed to next step to replace riv-nut(s). If no issue with the riv-nut is found, proceed to Step # 22. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7827 NOTE: The riv-nut procedure is applicable for vehicles built at the Windsor Assembly plant after May 24, 2004 or the St. Louis Assembly plant after June 28, 2004 or the Styler Assembly plant after June 28, 2004. Very few vehicles will require riv-nut replacement. 5. If the vehicle equipped with fog lamps, disconnect electrical harness connectors from both fog lamps. 6. Remove the 2 screws that secure the left and right wheelhouse splash shield to the front fascia. 7. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. 8. Remove the right and left fascia upper bolts from the upper radiator crossmember. (Fig 2) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7828 9. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Fig. 3) 10. Remove 2 vertical screws holding the front fascia to the front fender. 11. Carefully remove the front fascia and set aside. CAUTION: Care should be used not to damage painted surfaces. 12. Break the front air bag sensor using a suitable tool. Remove broken sensor pieces. 13. Using a powered cut-off wheel, remove the head of the sensor mounting bolt. 14. Remove sensor bushing from bolt. 15. Using a powered cut-off wheel, cut the bolt and lip of the riv-nut flush with sheet metal. 16. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. 17. Remove the old riv-nut through the access hole in the crossmember using a magnetic tool. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7829 18. Preassemble the new riv-nut, p/n CBX2G093 by installing the M6 nut, and the riv-nut onto the bolt, as shown in (Fig. 4). 19. Insert the riv-nut and bolt assembly into the original mounting hole. 20. Using a 10 mm crows foot, tighten the installation nut to 9 Nm, (80 in. lb) while holding the installation bolt stationary (Fig. 5). 21. Repeat Step # 12 through Step # 20 for remaining riv-nut(s) that have broken loose and spin freely. 22. Clean the mounting surface for both sensors. 23. Install the new sensors using the appropriate fasteners; Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7830 a. For sensors fastened with self-tapping bolts. Proceed to >>> # 24. b. For sensors fastened with M6 bolts and riv-nuts. Proceed to >>> Step # 26. 24. For self-tapping fastener installation; preassemble both air bag sensors with self-tapping bolts and washers (Fig. 6). 25. Position the sensors on the vehicle and tighten each self-tapping bolt into the mounting hole about 5 turns to cut new threads for the larger M7 bolt. Tighten to 7 Nm, (60 in. lb). Proceed to Step # 27. 26. For M6 bolt and riv-nut fastener installation; hand start both bolts in sensors. Tighten to 7 Nm, (60 in. lb). 27. Inspect the right and left air bag sensor wiring connectors. Is there is any sign of corrosion, (white, green or black), on either terminal of the harness connectors? a. Yes >>> Proceed to Step # 28. b. No >>> Proceed to Step # 39. NOTE: Only replace harness connectors that exhibit terminal corrosion. 28. Cut wire harness 3 in. (75 mm) back from connector. 29. Remove 1 in. (25 mm) of black tape from wire harness going to the vehicle. 30. Strip .5 in. (13 mm) of insulation from each wire. 31. Cut the new sensor connector wire harness p/n CBX2G092 the same length as the removed connector wire harness. 32. Strip .5 in. (13 mm) of insulation from each wire. 33. Slide one piece of heat shrink tubing on each of the wires. 34. Load and center the splice band into cavity "B" of crimp tool # 10042. Close the tool just enough to hold the splice band in place NOTE: First time use of crimp tool #10042 will require the crimp dies to be installed on the crimper frame. Orient the upper die with the arrow pointed up and the lower die with the arrow pointed forward. The numbers on upper die and letters on lower die will be on the same side. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7831 35. Match the new harness connector wires to the existing vehicle harness as follows: a. For the right (passenger side) sensor, match the new harness connector wire colors to the same color wire on the existing vehicle wire harness. b. For the left (driver side) sensor, match the new harness connector wire colors to the same tracer stripe color wire on the existing vehicle wire harness. CAUTION: Ensure wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 36. Insert the matched bare wires through the crimp connector from opposite ends. Crimp the connections using #10042 wire splice crimp tool. 37. Solder the crimped connection using only rosin-core solder. 38. Center heat shrink tubing over the connection and heat with a heat gun until tubing is tight and sealant is witnessed at the ends (Fig 7). CAUTION: Use only the sealant lined heat shrink tube supplied in wiring kit above. Use of electrical tape or non-sealant lined heat shrink tube may cause circuit failure. 39. Apply a small amount of dielectric grease, p/n J81 26688 to the airbag sensor connector end. Using a finger, force the grease into the terminal connections of the airbag sensor connector. 40. Connect the harness connectors to both front airbag sensors. 41. Has the fascia been removed? a. Yes >>> Proceed to Step # 42. b. No >>> Proceed to Step # 49. 42. Position the front fascia onto the vehicle. 43. Install the right and left upper fascia bolts, tighten to 5 Nm (50 in lb). 44. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender and tighten to 7 Nm (60 in lb). 45. Install the two vertical screws that secure the front fascia to the front fenders. 46. Install the two screws that secure the right and left wheelhouse shield to the front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 7832 47. Using new push pins, if necessary, securing the air dam to the lower radiator crossmember. 48. Connect the electrical harness connectors to the right and left fog lamps, if equipped. 49. Connect the negative battery cable to the battery. 50. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel, and turn the ignition key to the "ON position. Wait 10 seconds: a. If the airbag warning light is not illuminated, the repair is complete. Proceed to to clear stored DTC's. b. If the airbag warning light is illuminated due to supplemental front airbag sensor faults, switch the ignition key "OFF and Proceed to and clear any DTC's. If the DTC's return and ARE related to the Front Impact Sensor(s), Verify proper wiring connections as described in above. If wiring connections are correct, or if DTC's are related to other components of the supplemental airbag system, refer to the diagnostic information available in DealerCONNECT >>> TechCONNECT under: Diagnostics > 7.2 AIRBAG for further information. 51. Turn the ignition "OFF" and connect the DRBIII(R). NOTE: The DRBIII(R) must be at software Version 64.0 or later. 52. Turn the ignition key to "ON". 53. Press the "YES" button when the DRBIII(R) powers up. 54. Select "DRBIII(R) STANDALONE" and press "ENTER". 55. Select "1997-2007 DIAGNOSTICS" and press "ENTER". 56. Select "ALL" and press "ENTER". 57. Select "PASSIVE RESTRAINT" and press "ENTER". 58. Select "CLEAR DTCS". 59. Disconnect and remove the DRBIII(R) from the vehicle. 60. Reset clock. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement Technical Service Bulletin # J38 Date: 100420 Campaign - Front Air Bag Sensor Replacement April 2010 Dealer Service Instructions for: Customer Satisfaction Notification J38 Supplemental Front Airbag Sensors Models 2005-2006 (RS) Dodge Caravan, Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles built from January 19, 2005 through April 5, 2006 (MDH 011900 through 040500). IMPORTANT: Many of the vehicles within the above build period have already been repaired according to our warranty records, and therefore, have been excluded from this notification. Only the above vehicles originally sold or currently registered in certain states are involved. See the "Owner Notification and Service Scheduling" section for a list of states involved in this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The supplemental front airbag sensors on about 310,000 of the above vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Repair The right and left supplemental front airbag sensors must be replaced and the sensor wiring harness connectors must be inspected and replaced, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7838 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7839 Parts Information Special Tools The following special tools may be required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7840 Use the labor operation numbers and time allowances as shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicableable. Only vehicles originally sold or currently registered in the following states are involved in this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7841 To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure A. Supplemental Front Airbag Sensor Replacement 1. Lower the driver's window completely. 2. Open the hood. 3. Disconnect and isolate the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Raise the vehicle on a suitable hoist. 5. Disconnect the wiring harness connector to the right and left supplemental front airbag sensor. The sensors are located on the outside of the right and left frame rails at the radiator lower crossmember (Figure 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7842 6. Remove the right and left supplemental front airbag sensors and discard the sensors and retaining bolts. CAUTION: If the retaining bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose from the radiator lower crossmember. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensor retaining bolts, continue with Step 9. 7. Use the following procedure, if required, to replace a spun riv-nut: a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps. b. Remove the four screws (two each side) that secure the left and right wheelhouse splash shield to the front fascia. c. Remove the right and left side fascia-to-fender bolts. d. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. e. Partially lower the vehicle. f. Remove the right and left fascia bolts from the upper radiator crossmember (Figure 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7843 g. Pull the wheelhouse shield back from the front fascia and remove the right and left nuts holding the front fascia to the front lip of the fender (Figure 3). h. Carefully remove the front fascia and set it aside. CAUTION: Be careful not to scratch the painted surfaces of the front fascia and front fenders. i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard. j. Using a cut-off wheel, remove the head of the airbag sensor mounting bolt. k. Remove and discard the supplemental front airbag sensor bushing. l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool. NOTE: Be sure to completely remove the riv-nut from the lower radiator crossmember. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7844 n. Pre-assemble the new riv-nut by installing the installation nut and the riv-nut onto the installation bolt as shown in Figure 4. o. Insert the new riv-nut-bolt/nut assembly into the original riv-nut hole in the lower radiator crossmember. p. Using a 10mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5). q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut. r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely). 8. For vehicles that had the front fascia removed, use the following procedure to install the front fascia: a. Position the front fascia onto the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7845 b. Install the right and left upper fascia bolts finger tight (Figure 6). c. Install the right and left nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m). d. Install and tighten the two fascia-to-fender bolts. e. Install the four screws (two on each side) that secure the right and left wheelhouse shield to the front fascia. f. Using new push pins if necessary, install the air dam to the lower radiator crossmember. g. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps. h. Continue with Step 9. 9. Inspect the right and left supplemental front airbag sensor wiring connectors. > If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B. Airbag Sensor Harness Connector Replacement. > If there is no corrosion on either terminal of the harness connectors, continue with Section C. Supplemental Front Airbag Sensor Installation. B. Airbag Sensor Harness Connector(s) Replacement NOTE: Only those harness connector(s) that exhibit terminal corrosion, as described in Section A, require replacement. 1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector. 2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness. 3. Remove 1/2 inch (13 mm) of insulation from each wire. 4. Cut the new harness connector wires so that the final length is equal to the old harness. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7846 5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire. 6. Slide one piece of heat shrink tubing onto each of the harness connector wires. 7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just enough to hold the splice band in place. 8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows: > For the right (passenger side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the purple (w/blue tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the white (w/blue tracer) wire on the body wiring harness. > For the left (driver's side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the blue (w/purple tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the blue (w/white tracer) wire on the body wiring harness. CAUTION: Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band. 10. Crimp the splice band and wires together by squeezing the crimping tool handles. NOTE: The tool will release once the proper crimping force has been achieved. 11. Solder the connection together using only rosin core type solder. CAUTION: DO NOT use acid core solder. 12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing. CAUTION: Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure. 13. Continue with Section C. Supplemental Front Airbag Sensor Installation. C. Supplemental Front Airbag Sensor Installation 1. Clean the supplemental front airbag sensor mounting surface for both sensors. 2. Install the new supplemental front airbag sensors using the fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091. NOTE: Use the bolts with a blue thread locker patch on the threads. Discard the pointed self tapping screws and flat washers. They will not be used in this repair procedure. 3. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. 4. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7847 5. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector (Figure 7). NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor wiring harness connector. 6. Connect the wiring harness connectors to the right and left supplemental front airbag sensors. 7. Lower the vehicle from the hoist. 8. For vehicles that had the Fascia removed, tighten the upper fascia bolts to 50 in. lbs. (5 N.m). 9. Connect the negative battery cable to the battery. 10. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "RUN" position. Wait 10 seconds: > If the airbag warning light is not illuminated, the repair has been completed. No further action is required, return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 11 to clear the Diagnostic Trouble Codes (DTC's). 11. Use the following procedure to clear DTC's: a. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. b. Turn the ignition key to the "RUN" position. c. Press the "YES" button after the DRBIII powers up. d. Select "DRBIII STANDALONE" and press "ENTER". e. Select "1998-2007 DIAGNOSTICS" and press "ENTER". f. Select "ALL" and press "ENTER". g. Select "PASSIVE RESTRAINT" and press "ENTER". h. Select "AIRBAG" and press "ENTER". i. Select "READ DTC's" and press "ENTER". j. Select "STORED" and press "ENTER". k. Press the "PAGE BACK" button and follow the screen prompts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 7848 l. Disconnect and remove the DRBIII from the vehicle and return the vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement Technical Service Bulletin # G09 Date: 070601 Recall - Front Air Bag Impact Sensor Replacement June 2007 Dealer Service Instructions for: Customer Satisfaction Notification G09 Supplemental Front Airbag Sensors Models 2005 (RS) Dodge Caravan, Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles built at the Windsor Assembly plant ("R" in the 11th VIN position) through February 3, 2005 (MDH 020323) and the St. Louis Assembly plant ("B" in the 11th VIN position) through January 19, 2005 (MDH 011923). IMPORTANT: Many of the vehicles within the above build period have already been repaired according to our warranty records, and therefore, have been excluded from this notification. Only the above vehicles originally sold or currently registered in certain states are involved. See the "Owner Notification and Service Scheduling" section for a list of states involved in this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair service on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The supplemental front airbag sensors on about 263,000 of the above vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Repair The right and left supplemental front airbag sensors must be replaced and the sensor harness connectors must be inspected and replaced, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7853 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7854 Parts Information Special Tools The special tools may be required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record repair service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7855 Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Attached to each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Only vehicles originally sold or currently registered in the following states are involved in this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Supplemental Front Airbag Sensor Replacement 1. Lower the driver¡C■s window completely. 2. Open the hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7856 3. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Raise the vehicle on a suitable hoist. 5. Disconnect the harness connector to the right and left supplemental front airbag sensor (Figure 1). 6. Remove the right and left supplemental front airbag sensors and discard the bolts and sensors. NOTE: There are two types of bolts used to fasten the sensors to the radiator crossmember; an M7 self tapping bolt or an M6 bolt used with a riv-nut. If the bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensors, continue with Step 8. 7. Replaced a spun riv-nut as follows: NOTE: The following procedure is applicable for vehicle built at the Windsor Assembly Plant after May 24, 2004 or the St. Louis Assembly Plant after June 28, 2004. Very few vehicles are expected to require riv-nut replacement. a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps. b. Remove the two screws that secure the left and right wheelhouse splash shield to the front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7857 c Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. d. Partially lower the vehicle. e. Remove the right and left fascia upper bolts from the upper radiator crossmember (Figure 2). f. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Figure 3) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7858 g. Remove the two vertical screws holding the front fascia to the front fender. h. Carefully remove the front fascia and set it aside. CAUTION: Be careful not to scratch the painted surfaces of the front fascia and the front fenders. i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard. j. Using a cut-off wheel, cut off the head of the airbag sensor mounting bolt. k. Remove and discard the supplemental front airbag sensor bushing. l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool. NOTE: Be sure to completely remove the riv-nut from the lower radiator crossmember. n. Pre-assemble the new riv-nut by installing the M6 nut and the riv-nut onto the M6 bolt as shown in Figure 4. o. Insert the riv-nut-bolt/nut assembly into the body sheet metal hole. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7859 p. Using a 10 mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5). q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut. r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely). s. Clean the supplemental front airbag sensor mounting surface for both sensors. t. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091: > For sensors fastened with self tapping bolts: a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6. b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts. c. Tightening the self tapping bolts to 60 in.lbs. (7 N.m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7860 > For sensors fastened with M6 bolts and riv-nuts: a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). u. Inspect the right and left supplemental front airbag sensor wiring connectors. If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B Harness Connector Replacement. v. Position the front fascia onto the vehicle. w. Install the right and left upper bolts fascia bolts and tighten to 50 in. lbs. (5 N.m). x. Install the right and left horizontal nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m). y. Install and tighten the two vertical screws that secure the front fascia to the front fenders. z. Install the two screws that secure the right and left wheelhouse shield to the front fascia. aa. Using new push pins if necessary, install the air dam to the lower radiator crossmember. ab. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps. ac. Continue with Step 10. 8. Clean the supplemental front airbag sensor mounting surface for both sensors. 9. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091: > For sensors fastened with self tapping bolts: a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6. b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts. c. Tightening the self tapping bolts to 60 in. lbs. (7 N.m). > For sensors fastened with M6 bolts and riv-nuts: a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). 10. Inspect the right and left supplemental front airbag sensor wiring connectors. If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B - Harness Connector Replacement. 11. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector. NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector. 12. Connect harness connectors to the right and left supplemental front airbag sensors. 13. Lower the vehicle. 14. Connect the negative battery cable to the battery. 15. Stand next to the vehicle with the driver¡C■s door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "ON" position. Wait 10 seconds: > If the airbag warning light is not illuminated the repair has been completed. Return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7861 continue with Step 16 to clear the sensor DTC. 16. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. 17. Turn the ignition key to the "ON" position. 18. Press the "YES" button when the DRBIII powers up. 19. Select "DRBIII STANDALONE" and press "ENTER". 20. Select "1997-2007 DIAGNOSTICS" and press "ENTER". 21. Select "ALL" and press "ENTER" 22. Select "PASSIVE RESTRAINT" and press "ENTER". 23. Select "CLEAR DTCS". 24. Disconnect and remove the DRBIII from the vehicle. B. Airbag Sensor Harness Connector Replacement NOTE: Only those harness connectors that exhibit terminal corrosion, as described in Section A, require replacement. 1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector. 2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness. 3. Remove 1/2 inch (13 mm) of insulation from each wire. 4. Cut the new harness connector wires so that the final length is equal to the old harness. 5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire. 6. Slide one piece of heat shrink tubing onto each of the harness connector wires. 7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just the tool just CAUTION: The crimp jaw must be installed in the crimp tool frame as shown in Figure 7. The crimp jaw wire gauge numbers must be on the same side. When installing the crimp jaw into the tool frame, orient the upper die with the arrow pointed "up" and the lower die with the arrow pointed forward. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7862 8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows: > For the right (passenger side) supplemental front airbag sensor, match the new harness connector wire colors to the same color wire on the existing body wire harness. > For the left (driver's side) supplemental front airbag sensor, match the new harness connector wire colors to same tracer (stripe) color wire on the existing body wire harness. CAUTION: Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. warning lamp. 9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band (Figure 8). 10. Crimp the splice band and wires together by squeezing the crimping tool handles. The tool will release once the proper crimping force has been achieved (Figure 8). 11. Solder the connection together using only rosin-core type solder (Figure. 9). CAUTION: DO NOT use acid core solder. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7863 12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Figure 10). CAUTION: Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure. 13. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector. NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector. 14. Connect harness connectors to the right and left supplemental front airbag sensors. 15. For vehicles with the front fascia removed: a. Position the front fascia onto the vehicle. b. Install the right and left upper fascia bolts and tighten to 50 in. lbs. (5 N.m). c. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender. Tighten the nuts to 60 in. lbs. (7 N.m). d. Install and tighten the two vertical screws that secure the front fascia to the front fenders. e. Install the two screws that secure the right and left wheelhouse shield to the front fascia. f. Using new push pins if necessary, securing the air dam to the lower radiator crossmember. g. For vehicles with fog lamps, connect the electrical harness connectors to the right and left fog lamps. 16. Lower the vehicle. 17. Connect the negative battery cable to the battery. 18. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel, and turn the ignition key to the "ON" position. Wait 10 seconds: > If the airbag warning light is not illuminated, the repair has been completed. Return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 19 to clear the sensor DTC. 19. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. 20. Turn the ignition key to the "ON" position. 21. Press the "YES" button when the DRBIII powers up. 22. Select "DRBIII STANDALONE" and press "ENTER". 23. Select "1997-2007 DIAGNOSTICS" and press "ENTER". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 7864 24. Select "ALL" and press "ENTER". 25. Select "PASSIVE RESTRAINT" and press "ENTER". 26. Select "CLEAR DTCS". 27. Disconnect and remove the DRBIII from the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > NHTSA07V192000 > May > 07 > Recall 07V191000: Air Bag Impact Sensor Replacement Impact Sensor: All Technical Service Bulletins Recall 07V191000: Air Bag Impact Sensor Replacement MAKE/MODELS: MODEL/BUILD YEARS: Chrysler/Town & Country 2005 Dodge/Caravan 2005 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V192000 MFR'S REPORT DATE: May 01, 2007 COMPONENT: Air Bags: Frontal: Sensor/Control Module POTENTIAL NUMBER OF UNITS AFFECTED: 270958 SUMMARY: Certain minivans are being recalled that were originally sold in or currently registered in the 27 states plus The District of Columbia that use greater amounts of salt for Winter road deicing. The Up-Front (UF) air bag sensors that contain brass bushings installed in these vehicles may corrode and crack allowing water to enter the sensor. These sensors provide enhanced air bag performance in certain types of frontal crashes. CONSEQUENCE: In one of these crashes, with one or both of the vehicle the vehicle's UF sensors inoperative, the occupants will not benefit from the enhanced air bag protection that these sensors would provide. REMEDY: For vehicles registered in the recall states, dealers will replace the original UF air bag sensors with ones with greater corrosion resistance. Vehicles registered in other states will obtain a lifetime free replacement of any UF sensor that fails. The campaign is expected to begin during July 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler's campaign Nos. G09/X16. DaimlerChrysler has not decided that this is a defect related to motor vehicle safety. However, it has informed NHTSA that it will provide the modifications described above free of charge. Customers also may contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline aT 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Component Locations Impact Sensor: Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Component Locations > Page 7871 Impact Sensor: Connector Locations Left Fender Shield Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Component Locations > Page 7872 Right Side Body RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Component Locations > Page 7873 Right B Pillar Left B Pillar Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Component Locations > Page 7874 Left Rear Body Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Component Locations > Page 7875 Right Quarter Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7876 Impact Sensor: Diagrams Left Front Impact Sensor (Except Export Early Build) Left Front Impact Sensor (Export Early Build) Left Side Impact Sensor 1 (Except Export Early Build) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7877 Left Side Impact Sensor 1 (Export Early Build) Left Side Impact Sensor 2 Left Side Impact Sensor 3 (Except Export Late Build) Left Side Impact Sensor 3 (Export Late Build) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7878 Right Front Impact Sensor Right Side Impact Sensor 1 (Except Export Early Build) Right Side Impact Sensor 1 (Export Early Build) Right Side Impact Sensor 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7879 Right Side Impact Sensor 3 (Except Export Late Build) Right Side Impact Sensor 3 (Export Late Build) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Front Impact Sensors Impact Sensor: Description and Operation Front Impact Sensors Front Impact Sensor There are two front impact sensors, one on the left, and one on the right front sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). The right and left front and side impact sensors are identical in construction and calibration and each front impact sensor is secured with two screws. The front impact sensors are secured with two screws to the outboard sides of the right and left front rail tips. The impact sensor housing has an integral connector and two mounting ears, each with a metal sleeve to provide crush protection. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through the headlamp to dash wire harness. The front impact sensors cannot be repaired or adjusted and, if damaged or faulty, they must be replaced. If a front impact sensor is faulty, only the sensor needs to be replaced. If the sensor is damaged or faulty, or if proper tightening torque of the screws that secure the sensor to the bracket cannot be achieved, the sensor and bracket must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Front Impact Sensors > Page 7882 Impact Sensor: Description and Operation Side Impact Sensors Side Impact Sensor Side Impact Sensor Location Three side impact sensors are used on each side of the vehicle. These sensors are mounted remotely from the bi-directional safing sensor that is internal to the Occupant Restraint Controller (ORC). The side and front impact sensors are identical in construction and calibration and each impact sensor is secured with two screws. Each side impact sensor is secured with two screws. The first row side impact sensor is located in the B-pillar, just above the front seat belt retractor. The second row side impact sensor is located in the sliding door opening, in the lower door track area. The third row side impact sensor is located behind the quarter trim panel, above the rear tire wheel well, between the C and D-pillars. The impact sensor housing has an integral connector. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a connector of the body harness. The side impact sensors cannot be repaired or adjusted. If damaged or faulty, they must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor Impact Sensor: Service and Repair Front Impact Sensor REMOVAL. The right and left front impact sensors are mounted identically on the front rail tips. 1. Open hood, disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG SYSTEM OR COMPONENT SERVICE. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, PERSONAL INJURY OR DEATH. 2. Hoist vehicle. Front Impact Sensor Remove/Install 3. Disconnect electrical connector. 4. Remove the two screws attaching front impact sensor to outer rails. 5. Remove sensor from vehicle. INSTALLATION 1. Position sensor in vehicle. 2. Install the two retaining screws to the impact sensor. Torque screws to 7 Nm (62 in. lbs.). 3. Connect electrical connector. 4. Lower vehicle from hoist. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. 5. Verify vehicle and system operation. 6. Close hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor > Page 7885 Impact Sensor: Service and Repair Side Impact Sensors B-Pillar Mounted REMOVAL The right and left front row side impact sensors, are mounted identically, on opposite sides of the vehicle, in the b-pillar. 1. Open hood, disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG COMPONENT SERVICE. PERSONAL INJURY OR DEATH MAY RESULT. 2. Remove the B-pillar lower trim for the side of the vehicle that you are replacing the side impact sensor. Front Row Side Impact Sensor And Bracket 3. Disconnect the electrical connector from the impact sensor. 4. Remove the four retaining screws to the impact sensor bracket. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor > Page 7886 Front Row Side Impact Sensor/Bracket 5. Remove impact sensor from vehicle. INSTALLATION 1. Position sensor bracket in vehicle. 2. Install the four retaining screws to the impact sensor bracket. Torque screws to 7 Nm (62 in. lbs.). 3. Connect the electrical connector. 4. Install the B-pillar lower trim for the side of the vehicle that you are replacing the side impact sensor. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. 5. Verify vehicle and system operation. 6. Close hood. Sliding Door Opening Mounted REMOVAL The right and left second row side impact sensors, are mounted identically, on opposite sides of the vehicle, in the sliding door opening lower rear where the lower roller arm mounts in the lower door track. 1. Open hood, disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG COMPONENT SERVICE. PERSONAL INJURY OR DEATH MAY RESULT. 2. Open sliding door to the fullest open position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor > Page 7887 2nd Row Side Impact Sensor 3. Remove the two retaining screws to the impact sensor. 4. Disconnect the electrical connector from the impact sensor and remove from vehicle. INSTALLATION 1. Connect electrical connector. 2. Position sensor in vehicle. 3. Install the two retaining screws to the impact sensor. Torque screws to 7 Nm (62 in. lbs.). WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. 4. Verify vehicle and system operation. 5. Close hood. Quarter Panel Mounted REMOVAL 1. Open hood, disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG COMPONENT SERVICE. PERSONAL INJURY OR DEATH MAY RESULT. 2. Remove the quarter trim panel for the side of the vehicle that you are replacing the side impact sensor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor > Page 7888 3rd Row Side Impact Sensor 3. Remove the two retaining screws to the impact sensor. 4. Disconnect the electrical connector from the impact sensor and remove from vehicle. INSTALLATION 1. Position sensor in vehicle. 2. Connect electrical connector. 3. Install the two retaining screws to the impact sensor. Torque screws to 7 Nm (62 in. lbs.). 4. Install the quarter trim panel for the side of the vehicle that you are replacing the side impact sensor. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. 5. Verify vehicle and system operation. 6. Close hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Diagrams Seat Occupant Sensor: Diagrams Passenger Seat Weight Sensor Occupant Classification Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Diagrams Passenger Airbag On/Off Indicator Lamp Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Service and Repair > Child Seat Module, Bench Seat Child Seat: Service and Repair Child Seat Module, Bench Seat CHILD SEAT MODULE, BENCH SEAT REMOVAL 1. Close child restraint seat. 2. Remove seat back cover. Fig. 1 3. Remove screws attaching child restraint seat module hinges to seat back frame lower rail (Fig. 1). 4. Return seat back to upright position. Fig. 2 5. Disengage push in fasteners attaching upper bolster to child restraint seat module (Fig. 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Service and Repair > Child Seat Module, Bench Seat > Page 7899 Fig. 3 6. Remove screws attaching top of module to seat back frame upper rail (Fig. 3). Fig. 4 7. Remove child restraint seat module from seat back (Fig. 4). INSTALLATION INSTALLATION 1. Place child restraint seat module in position on seat back (Fig. 4). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Service and Repair > Child Seat Module, Bench Seat > Page 7900 Fig. 5 2. Position seat back hinge interlock lever over the top of the outboard child restraint seat hinge (Fig. 5). 3. Install screws attaching child restraint seat module hinges to seat back frame lower rail (Fig. 1). 4. Install screws attaching top of module to seat back frame upper rail (Fig. 3). Tighten nuts to 7 N.m (62 in.lbs.) torque. 5. Install push in fasteners attaching upper bolster to child restraint seat module (Fig. 2). 6. Return seat back to folded position. 7. Install seat back cover. 8. Check belt for smooth operation and verify interlock operation. Recliner should not operate with child seat deployed. SYNCHRONIZING CABLE ADJUSTMENT NOTE: Bench seats equipped with child restraint seats have an interlock feature that will not allow the seat back to fold forward with the child seat open. If the seat back hinges do not release at the same time the synchronizing cable must be adjusted. 1. Remove seat from vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Service and Repair > Child Seat Module, Bench Seat > Page 7901 Fig. 6 2. Disengage cable from the recline mechanism by pulling the cable end toward the front of the seat (Fig. 6). 3. Pull U-shaped locking tab on self-adjusting mechanism to disengage auto-adjust feature. 4. Reattach self-adjusting mechanism, pulling against spring load to tighten cable. 5. Press locking tab onto the adjusting mechanism to lock into place. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Service and Repair > Child Seat Module, Bench Seat > Page 7902 Child Seat: Service and Repair Quad Child Seat QUAD CHILD SEAT REMOVAL 1. Remove the seat. Fig. 7 2. Remove seat back cover (Fig. 7). Fig. 8 3. Remove fasteners attaching quad child seat to the seat (Fig. 8). 4. Remove quad child seat from the seat. INSTALLATION 1. Place quad child seat in position. 2. Install fasteners and tighten to 13.5 N.m (10 ft.lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Service and Repair > Child Seat Module, Bench Seat > Page 7903 3. Install seat back cover. 4. Install seat in vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Locations > Page 7907 Knee Diverter: Service and Repair REMOVAL 1. Remove lower steering column cover 2. Remove the park brake release handle link from the park brake release handle. Inflatable Knee Blocker 3. Disengage inflatable knee blocker wire connector from lower instrument and disconnect the wire connector. 4. Remove screws attaching to instrument panel. 5. Remove inflatable knee blocker from vehicle. INSTALLATION 1. Place inflatable knee blocker into position. 2. Connect inflatable knee blocker wire connector and install inflatable knee blocker attaching screws. 3. Install the steering column cover backing plate into vehicle. 4. Install park brake release handle link to park brake release handle. 5. Install the lower steering column cover. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7912 Air Bag Control Module: Diagrams Occupant Restraint Controller C1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7913 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7914 Occupant Restraint Controller C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7915 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7916 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7917 Air Bag Control Module: Description and Operation Occupant Restraint Controller - Typical The Occupant Restraint Controller (ORC) is also sometimes referred to as the Airbag Control Module (ACM). ORC Location The ORC is secured with screws to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel just behind and underneath the instrument panel center stack in the passenger compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with four screws to enclose and protect the internal electronic circuitry and components. An arrow printed on the label on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has integral mounting flanges, the ORC has two molded plastic electrical connectors that exits the right facing side of the ORC housing. These terminal pins connect the ORC to the vehicle electrical system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7918 The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for vehicles with or without curtain airbags. The ORC cannot be repaired or adjusted and, if damaged or faulty, it must be replaced. The microprocessor in the Occupant Restraint Controller (ORC) contains the supplemental restraint system logic circuits and controls all of the supplemental restraint system components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Programmable Communication Interface (PCI) data bus. This method of communication is used for control of the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and for supplemental restraint system diagnosis and testing through the 16-way Data Link Connector (DLC) located on the driver side lower edge of the instrument panel. The ORC microprocessor continuously monitors all of the supplemental restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the PCI data bus to turn on the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTC's, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. On models equipped with the Occupant Classification System (OCS), the ORC communicates with the Occupant Classification Module (OCM) over the PCI data bus. The ORC will internally disable the passenger airbag and seat belt tensioner deployment circuits if the OCM detects that the passenger side front seat is unoccupied or that it is occupied by a load that is inappropriate for an airbag deployment. The ORC also provides a control output to the Passenger Airbag Disabled (PAD) indicator through the passenger airbag indicator driver circuit. The OCM notifies the ORC when it has detected a monitored system fault and stored a DTC in its memory for any faulty OCS component or circuit, then the ORC sets a DTC and controls the airbag indicator operation accordingly. The ORC receives battery current through two circuits; a fused ignition switch output (RUN) circuit through a fuse in the Junction Block (JB), and a fused ignition switch output (RUN/START) circuit through a second fuse in the JB. The ORC receives ground through a ground circuit of the instrument panel wire harness. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the front supplemental restraint components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup supplemental restraint system protection in case there is a loss of battery current supply to the ORC during an impact. Two sensors are contained within the ORC, an electronic impact sensor and a safing sensor. The ORC also monitors inputs from eight remote impact sensors. Two front impact sensors are located on each outboard side of the lower radiator support, and three side impact sensors are located on each side of the vehicle at the B-pillar, in the lower sliding door opening in front of the C-pillar, and over the rear wheel well between the C and D-pillars. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The safing sensor is an electronic accelerometer sensor within the ORC that provides an additional logic input to the ORC microprocessor. The safing sensor is used to verify the need for a supplemental restraint deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. Vehicles equipped with curtain airbags, there is a second safing sensor within the ORC to provide confirmation to the ORC microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require supplemental restraint system protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and, if the vehicle is so equipped, either curtain airbag. For vehicles equipped with the OCS, the passenger front airbag and seat belt tensioner will be deployed by the ORC only if enabled by the OCM messages (PAD indicator OFF) at the time of the impact. To diagnose and test the ORC and all airbag system components, use a scan tool and the appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7919 Air Bag Control Module: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS), NEVER REPLACE BOTH THE OCCUPANT RESTRAINT CONTROLLER (ORC) AND THE OCCUPANT CLASSIFICATION MODULE (OCM) AT THE SAME TIME. IF BOTH REQUIRE REPLACEMENT, REPLACE THE OCM FIRST. THEN PERFORM THE AIRBAG SYSTEM TEST INCLUDING AN IGNITION-ON TIME OF AT LEAST ONE MINUTE BEFORE REPLACING THE ORC. BOTH THE ORC AND THE OCM STORE OCS CALIBRATION DATA, WHICH THEY TRANSFER TO ONE ANOTHER DURING THE FIRST MINUTE OF IGNITION-ON TIME AFTER ONE OF THEM IS REPLACED. IF BOTH MODULES ARE REPLACED AT THE SAME TIME, AN IRREVERSIBLE FAULT WILL BE SET IN BOTH MODULES. 1. Disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG SYSTEM OR COMPONENT SERVICE. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, PERSONAL INJURY OR DEATH. 2. Remove storage bin from instrument panel. ORC - Remove/Install 3. Remove three bolts holding ORC to floor bracket. 4. Disconnect the wire connectors from the ORC. 5. Remove the ORC from vehicle. INSTALLATION WARNING: - DO NOT INSTALL ORC IF MOUNTING LOCATION IS DEFORMED OR DAMAGED. THIS WILL CAUSE THE ORC TO BE IMPROPERLY LOCATED AND COULD RESULT IN OCCUPANT PERSONAL INJURY OR DEATH. - USE CORRECT SCREWS WHEN INSTALLING THE ORC. - NEVER REPLACE BOTH THE OCCUPANT RESTRAINT CONTROLLER (ORC) AND THE OCCUPANT CLASSIFICATION MODULE (OCM) AT THE SAME TIME. IF BOTH REQUIRE REPLACEMENT, REPLACE ONE, THEN PERFORM THE AIRBAG SYSTEM TEST BEFORE REPLACING THE OTHER. BOTH THE ORC AND THE OCM STORE OCCUPANT CLASSIFICATION SYSTEM (OCS) CALIBRATION DATA, WHICH THEY TRANSFER TO ONE ANOTHER WHEN ONE OF THEM IS REPLACED. IF BOTH ARE REPLACED AT THE SAME TIME, AN IRREVERSIBLE FAULT WILL BE SET IN BOTH MODULES AND THE OCS MAY MALFUNCTION AND RESULT IN PERSONAL INJURY OR DEATH. 1. Install the ORC into vehicle. 2. Connect the wire connector to the ORC. 3. Install three bolts holding ORC to floor bracket. Torque bolts to 7.3 - 9.6 Nm (65 to 85 in. lbs.) 4. Install the storage bin onto the instrument panel. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7920 SYSTEM TEST IS NOT PERFORMED FIRST. 5. Verify vehicle and system operation. 6. Close hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 7926 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 7927 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Page 7928 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation Child Seat Tether Attachment: Description and Operation Child Restraint Upper Tether/Anchor - 2nd Row Child Restraint Lower Anchors Second Row The Lower Anchors and Tether for Children, or LATCH child restraint anchorage system provides for the installation of suitable child restraints in certain seating positions without using the seat belt provided for that seating position. The second seat in these models are equipped with a fixed-position child restraint upper tether anchor and child restraint lower anchors. The third seat is equipped with only a fixed-position child restraint upper tether anchor in the middle seating position. Export vehicles are equipped with fixed-position child restraint upper tether anchors only. The second row seats have lower anchors for each rear outboard seating position. These anchors are welded to the seat cushion frame. They are each accessed from the front of their respective seats, at each side where the seat back meets the seat cushion. These lower anchors cannot be adjusted or repaired and, if faulty or damaged, the seat must be replaced as a unit. WARNING: DURING, AND FOLLOWING, ANY CHILD RESTRAINT ANCHOR SERVICE, DUE TO IMPACT EVENT OR VEHICLE REPAIR, CAREFULLY INSPECT ALL MOUNTING HARDWARE, TETHER STRAPS AND ANCHORS FOR PROPER INSTALLATION, OPERATION, OR DAMAGE. IF A CHILD RESTRAINT ANCHOR IS FOUND DAMAGED IN ANY WAY, THE ANCHOR MUST BE REPLACED WITH THE SEAT ASSEMBLY. FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY OR DEATH. See the vehicle glove box for more information on the proper use of all of the factory-installed child restraint anchors. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Page 7933 Tether Strap Placement - Rear Seat Delete Tether Strap Installed - Rear Seat Delete REAR SEAT DELETE If the vehicle is ordered without rear seats (rear seat delete), then there will be a tether strap included. This is to be looped under the second seat anchor and then extended forward to clip to the tether strap of the child seat in the front passenger seat. There will be no lower anchor loops for child seat anchoring in the front passenger seat. Use the seat belt for lower child seat attachment in this instance. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Procedures Seat Belt: Procedures Seat Belt & Retractor Outboard-Front REMOVAL 1. Open door. 2. Move seat all the way forward. 3. Open hood. 4. Disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG SYSTEM OR COMPONENT SERVICE. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, PERSONAL INJURY OR DEATH. Seat Belt - Outboard Front 5. Remove shoulder harness height adjuster knob by pulling it straight away from adjuster. 6. Remove cover from seat belt turning loop. 7. Remove bolt attaching turning loop to shoulder belt height adjuster. 8. Remove upper B-pillar trim cover. NOTE: If equipped with the Occupant Classification System (OCS), there is a Belt Tension Sensor located on the lower seat belt anchor on the passenger front seat belt. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Procedures > Page 7938 Belt Tension Sensor/Lower Seat Belt Anchor 9. Remove the lower seat belt anchor bolt. 10. Disconnect the electrical connector if equipped with OCS. 11. Remove front door sill plate. 12. Remove sliding door sill plate. 13. Remove lower B-pillar trim cover. 14. Disconnect the seat belt retractor electrical connector. 15. Remove seat belt retractor attaching bolt. 16. Remove the seat belt and retractor from vehicle. INSTALLATION WARNING: INSPECT THE CONDITION OF THE SHOULDER BELT AND LAP BELT. REPLACE ANY BELT THAT IS CUT, FRAYED, TORN, OR DAMAGED IN ANY WAY. ALSO, REPLACE THE SHOULDER BELT IF THE RETRACTOR IS EITHER DAMAGED OR INOPERATIVE. 1. Place seat belt and retractor into position. 2. Install bolt attaching seat belt retractor to B-pillar. Torque bolt to 39 Nm (29 ft. lbs.). 3. Connect the seat belt retractor electrical connector. 4. Install the lower B-pillar trim cover. 5. Install the sliding door sill plate. 6. Install the front door sill plate. 7. Install the lower seat belt anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). NOTE: If equipped with the Occupant Classification System (OCS), there is a Belt Tension Sensor located on the lower seat belt anchor on the passenger front seat belt. 8. Connect the belt tension sensor connector (if equipped with OCS). 9. Install the upper B-pillar trim cover. 10. Install the bolt attaching turning loop to shoulder belt height adjuster. Torque bolt to 39 Nm (29 ft. lbs.). 11. Install the cover to the seat belt turning loop. 12. Install the shoulder harness height adjuster knob by pushing it straight onto the adjuster. 13. Move seat back to approximate customer position. WARNING: - IF EQUIPPED WITH THE OCS, DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. - IF EQUIPPED WITH THE OCS, FOLLOWING SUCCESSFUL COMPLETION OF THE AIRBAG SYSTEM TEST PROCEDURE, THE OCCUPANT CLASSIFICATION SYSTEM VERIFICATION TEST MUST BE DONE USING A SCAN TOOL AND THE APPROPRIATE DIAGNOSTIC INFORMATION. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Procedures > Page 7939 14. Verify vehicle and system operation. 15. Close hood. Seat Belt & Retractor-First Row-Outboard REMOVAL 1. Remove first and second row seats. 2. Remove first row seat belt lower anchor bolt. 3. Remove first row seat belt upper turning loop anchor bolt. 4. Remove liftgate sill plate. Remove second seat lower anchor bolt. 5. Remove upper liftgate trim. 6. Remove second seat lower anchor bolt. 7. Remove second seat upper turning loop anchor bolt. 8. Remove D-pillar trim cover. 9. Disconnect speaker connector. The left side has the speaker mounted in the D-pillar trim cover and the right side will have the speaker mounted in the rear of the quarter trim panel, but the connector is accessible from the rear after the D-pillar trim is removed. 10. Remove quarter trim bolster. 11. Remove quarter trim panel screws. 12. Remove quarter trim panel. 13. Remove first row seat belt and retractor retaining bolt. 14. Remove first row seat belt and retractor from vehicle. INSTALLATION 1. Install first row seat belt and retractor. Torque bolt to 39 Nm (29 ft. lbs.). 2. Install quarter trim panel. 3. Install quarter trim panel screws. 4. Install quarter trim bolster. 5. Connect speaker connector. The left side has the speaker mounted in the D-pillar trim cover and the right side will have the speaker mounted in the rear of the quarter trim panel, but the connector is accessible from the rear after the D-pillar trim is removed. 6. Install D-pillar trim cover. 7. Install second seat belt lower anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 8. Install second seat belt upper turning loop anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 9. Install upper liftgate trim. 10. Install liftgate sill plate. 11. Install first row seat belt upper turning loop anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 12. Install first row seat belt lower anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 13. Install first and second row seats. Seat Belt & Retractor-Second Row-Right Outboard REMOVAL 1. Remove first and second row seats. 2. Remove first row seat belt lower anchor bolt. 3. Remove first row seat belt upper anchor bolt. 4. Remove liftgate sill plate. 5. Remove upper liftgate trim. 6. Remove second seat belt lower anchor bolt. 7. Remove second seat belt upper anchor bolt. 8. Remove D-pillar trim cover. 9. Disconnect speaker connector. The left side has the speaker mounted in the D-pillar trim cover and the right side will have the speaker mounted in the rear of the quarter trim panel, but the connector is accessible from the rear after the D-pillar trim is removed. 10. Remove quarter trim bolster. 11. Remove quarter trim panel screws. 12. Remove quarter trim panel. 13. Remove retractor retaining bolt. 14. Remove second row seat belt and retractor. INSTALLATION 1. Install second row seat belt and retractor. Torque bolt to 39 Nm (29 ft. lbs.). 2. Install quarter trim panel. 3. Install quarter trim panel screws. 4. Install quarter trim bolster. 5. Connect speaker connector. The left side has the speaker mounted in the D-pillar trim cover and the right side will have the speaker mounted in the rear of the quarter trim panel, but the connector is accessible from the rear after the D-pillar trim is removed. 6. Install D-pillar trim cover. 7. Install second seat belt lower anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Procedures > Page 7940 8. Install second seat belt upper turning loop anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 9. Install upper liftgate trim. 10. Install liftgate sill plate. 11. Install first row seat belt upper turning loop anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 12. Install first row seat belt lower anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 13. Install first and second row seats. Seat Belt & Retractor-Second Row-Right Outboard With Rear HVAC-LWB REMOVAL 1. Remove first and second row seats. 2. Remove first row seat belt lower anchor bolt. 3. Remove first row seat belt upper anchor bolt. 4. Remove liftgate sill plate. 5. Remove upper liftgate trim. 6. Remove second seat belt lower anchor bolt. 7. Remove second seat belt upper anchor bolt. 8. Remove D-pillar trim cover. 9. Disconnect speaker connector. The left side has the speaker mounted in the D-pillar trim cover and the right side will have the speaker mounted in the rear of the quarter trim panel, but the connector is accessible from the rear after the D-pillar trim is removed. 10. Remove quarter trim bolster. 11. Remove quarter trim panel screws. 12. Remove quarter trim panel. 13. Loosen HVAC unit enough to gain access to seat belt retractor fasteners. Trim Panel Mounting Bracket a. Remove bracket around HVAC unit. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Procedures > Page 7941 Lower Heater Duct b. Remove air duct. Rear HVAC Mounting c. Remove fasteners attaching HVAC unit to inner quarter panel. d. Gently pry out on rear HVAC unit to gain access to the seat belt and retractor. 14. Remove bolts attaching seat belt guide loop to inner quarter panel. 15. Pull outward on HVAC unit and remove bolt attaching retractor to inner quarter panel. 16. Remove second row seat belt and retractor from vehicle. INSTALLATION 1. Position second row seat belt and retractor to vehicle. 2. Pull outward on HVAC unit and install bolt attaching retractor to inner quarter panel. Torque bolt to 39 Nm (29 ft. lbs.). 3. Install bolts attaching seat belt guide loop to inner quarter panel. 4. Install fasteners attaching HVAC unit to inner quarter panel. 5. Install air duct. 6. Install trim panel retaining bracket around HVAC unit. 7. Install quarter trim panel. 8. Install quarter trim panel screws. 9. Install quarter trim bolster. 10. Connect speaker connector. The left side has the speaker mounted in the D-pillar trim cover and the right side will have the speaker mounted in the rear of the quarter trim panel, but the connector is accessible from the rear after the D-pillar trim is removed. 11. Install D-pillar trim cover. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Procedures > Page 7942 12. Install second seat belt lower anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 13. Install second seat belt upper turning loop anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 14. Install upper liftgate trim. 15. Install liftgate sill plate. 16. Install first row seat belt upper turning loop anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 17. Install first row seat belt lower anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 18. Install first and second row seats. Seat Belt & Retractor-Second Row-Left Outboard REMOVAL 1. Remove first and second row seats. 2. Remove first row seat belt lower anchor bolt. 3. Remove first row seat belt upper anchor bolt. 4. Remove liftgate sill plate. 5. Remove upper liftgate trim. 6. Remove second seat belt lower anchor bolt. 7. Remove second seat belt upper anchor bolt. 8. Remove D-pillar trim cover. 9. Disconnect speaker connector. The left side has the speaker mounted in the D-pillar trim cover and the right side will have the speaker mounted in the rear of the quarter trim panel, but the connector is accessible from the rear after the D-pillar trim is removed. 10. Remove quarter trim bolster. 11. Remove quarter trim panel screws. 12. Remove quarter trim panel. 13. Remove retractor retaining bolt. 14. Remove second row seat belt and retractor from vehicle. INSTALLATION 1. Install second row seat belt and retractor. Torque bolt to 39 Nm (29 ft. lbs.). 2. Install quarter trim panel. 3. Install quarter trim panel screws. 4. Install quarter trim bolster. 5. Connect speaker connector. The left side has the speaker mounted in the D-pillar trim cover and the right side will have the speaker mounted in the rear of the quarter trim panel, but the connector is accessible from the rear after the D-pillar trim is removed. 6. Install D-pillar trim cover. 7. Install second seat belt lower anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 8. Install second seat belt upper turning loop anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 9. Install upper liftgate trim. 10. Install liftgate sill plate. 11. Install first row seat belt upper turning loop anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 12. Install first row seat belt lower anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 13. Install first and second row seats. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Procedures > Page 7943 Seat Belt: Removal and Replacement SEAT BELT CENTER LAP BELT - STOW - N - GO REMOVAL 1. Remove seat back assembly. Fig. 114 2. Remove recliner mechanism. (Fig. 114). 3. Remove cushion cover/foam. Fig. 115 4. Remove nut attaching center belt from the cushion pan. (Fig. 115). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Procedures > Page 7944 Fig. 116 5. Using a trim tool, remove seat cushion pan bottom side panel (Fig. 116). 6. Remove handle from cushion. 7. Remove seat cushion cover and foam from cushion pan. 8. Remove nut attaching center tip half and buckle together. Fig. 117 9. Remove center tip half and buckle from seat (Fig. 117). INSTALLATION 1. Install center lap belt with nut. Tighten nut to 60 N.m (44 ft.lbs.) 2. Install cushion cover/foam. 3. Install recliner mechanism. 4. Install seat back assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle-Front Inboard Seat Belt Buckle: Service and Repair Seat Belt Buckle-Front Inboard REMOVAL The seat belt tensioners are integral to the front seat belt buckles. They are not serviceable and must be replaced after a frontal impact event. The entire front seat belt buckle assembly must be replaced as an assembly. 1. Open hood. 2. Disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG SYSTEM OR COMPONENT SERVICE. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, PERSONAL INJURY OR DEATH. 3. Remove screws attaching front inboard side cover to seat cushion frame. 4. Remove side cover from front seat. 5. Disconnect the tensioner wire connector from seat belt buckle. 6. Remove bolt attaching seat belt buckle to front seat track. 7. Remove buckle from seat. INSTALLATION The seat belt tensioners are integral to the front seat belt buckles. They are not serviceable and must be replaced after a frontal impact event. The entire front seat belt buckle assembly must be replaced as an assembly. 1. Place buckle into position. 2. Install bolt attaching seat belt buckle to front seat track. Torque bolt to 39 Nm (29 ft. lbs.). 3. Connect the seat belt tensioner electrical connector. 4. Install side cover into position. 5. Install screws attaching front inboard side cover to seat cushion frame. WARNING: - DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. - IF EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS) AND REPLACING THE PASSENGER FRONT SEAT BELT BUCKLE: FOLLOWING SUCCESSFUL COMPLETION OF THE AIRBAG SYSTEM TEST PROCEDURE, THE OCCUPANT CLASSIFICATION SYSTEM VERIFICATION TEST MUST BE DONE USING A SCAN TOOL AND THE APPROPRIATE DIAGNOSTIC INFORMATION. 6. Close hood. 7. Verify system and vehicle operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle-Front Inboard > Page 7949 Seat Belt Buckle: Service and Repair Seat Belt Buckle-Row Inboard-Quad Bucket Quad Bucket REMOVAL 1. Remove seat from vehicle. 2. Remove screws attaching inboard side cover to seat cushion. 3. Remove side cover from seat. 4. Remove bolts attaching recliner bracket to seat cushion. 5. Remove recliner bracket from seat. 1st Row Inboard Buckle - Quad Bucket 6. Remove bolt attaching seat belt buckle to seat track. 7. Remove buckle from vehicle. INSTALLATION 1. Place buckle into position. 2. Install bolt attaching seat belt buckle to seat track. Torque bolt to 39 Nm (29 ft. lbs.). 3. Install recliner bracket onto the seat. 4. Install bolts attaching recliner bracket to seat cushion. 5. Install side cover from seat. 6. Install screws attaching inboard side cover to seat cushion. 7. Install seat into position. Quad Bucket-Fold In Floor REMOVAL 1. Fold in floor the seat not having the buckle replaced. 2. Remove the hinge cover retaining screw and hinge cover. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle-Front Inboard > Page 7950 1st Row Inboard Buckle Retaining Bolts - Fold In Floor 3. Remove the hinge retaining bolts under the cushion cover side panel. 1st Row Inboard Buckle - Fold In Floor 4. Gently lift hinge upwards to free buckle from between the cushion frame and the hinge itself. 5. Remove buckle half from seat. INSTALLATION 1. Gently lift hinge upwards and place buckle in between the cushion frame and the hinge itself. 2. Install the hinge retaining bolts under the cushion cover side panel. 3. Install the hinge cover retaining screw and hinge cover. Seat Belt Buckle-First Row-Bench REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle-Front Inboard > Page 7951 1. Remove seat from vehicle. Seat Belt Buckle - First Row - Bench 2. Remove bolt attaching inboard seat belt buckle to seat frame. 3. Remove belt from seat. INSTALLATION 1. Place seat belt into position to the seat. 2. Install bolt attaching inboard seat belt buckle to seat frame. Tighten all seat belt anchor bolts to 39 Nm (29 ft. lbs.) torque. 3. Install seat into position. Second Row 50/50 Bench REMOVAL 1. Open rear liftgate. 2. Pull handle #1 and fold seat back forward. 3. Pull handle #2, and lift seat bottom up. 4. Pull #3 strap and remove seat from latching area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle-Front Inboard > Page 7952 Seat Belt Buckle - Second Row Inboard - 50/50 Bench 5. While looking at the bottom of the seat, locate retaining bolt on the left side of the seat riser. Remove retaining bolt from seat riser. 6. Pull belt through seat cushion. INSTALLATION 1. Push belt through seat cushion. 2. While looking at the bottom of the seat, locate retaining bolt hole on the left side of the seat riser. Install retaining bolt into seat riser. Torque anchor bolt to 39 Nm (29 ft. lbs.). 3. Place seat into track and on front anchors. 4. Pull #3 strap and install seat onto latching area. 5. Pull seat assembly down firmly and snap into track. 6. Pull handle #1 and fold seat back rearward. 7. Close rear liftgate. Second Row-Fold In Floor REMOVAL 1. Fold in floor the seat not having the buckle replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle-Front Inboard > Page 7953 First Row Buckle - Inboard - Cover Retaining Screw 2. Remove the hinge cover retaining screw. First Row Buckle - Inboard - Retaining Nut 3. Pull hinge cover out just far enough to gain access to buckle retaining nut. Remove nut and slide buckle out from under cushion cover side panel. INSTALLATION 1. Push belt through seat cushion. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle-Front Inboard > Page 7954 Seat Belt Buckle - Second Row Inboard - 50/50 Bench 2. While looking at the bottom of the seat, locate retaining bolt hole on the left side of the seat riser. Install retaining bolt into seat riser. Torque anchor bolt to 39 Nm (29 ft. lbs.). 3. Place seat into track and on front anchors. 4. Pull #3 strap and install seat onto latching area. 5. Pull seat assembly down firmly and snap into track. 6. Pull handle #1 and fold seat back rearward. 7. Close rear liftgate. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle-Front Inboard > Page 7955 Seat Belt Buckle: Service and Repair Seat Belt Buckle-Second Row-Three Passenger REMOVAL Seat Belt Buckle - Second Row - Three Passenger Bench 1. Remove bolt attaching seat belt buckle to seat rear frame rail. 2. Remove seat belt buckle from seat. INSTALLATION 1. Place seat belt buckle in position on seat. 2. Install bolt to attach seat belt buckle to seat rear frame rail. Tighten all seat belt bolts to 39 Nm (29 ft. lbs.) torque. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 7959 Seat Belt Buckle Switch: Diagrams Driver Seat Belt Switch Passenger Seat Belt Switch (Early Build Occupant Sensing) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Seat Belt Height Adjuster-B or C-Pillar Seat Belt Height Adjuster: Service and Repair Seat Belt Height Adjuster-B or C-Pillar REMOVAL 1. Remove turning loop retaining bolt. 2. Remove B or C-pillar trim cover. 3. Remove two screws attaching shoulder belt height adjuster to pillar. 4. Remove height adjuster from vehicle. INSTALLATION 1. Place height adjuster into position. 2. Install screws attaching shoulder belt height adjuster to pillar. 3. Install B or C-pillar trim cover. 4. Install turning loop to height adjuster. Torque anchor bolt to 39 Nm (29 ft. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Seat Belt Height Adjuster-B or C-Pillar > Page 7964 Seat Belt Height Adjuster: Service and Repair Seat Belt Height Adjuster Knob REMOVAL 1. Disengage clips attaching clam shell cover to seat belt turning loop and open cover. 2. Using a trim tool (special tool #C-4755), gently pry knob from seat belt height adjuster. INSTALLATION 1. Place seat belt height adjuster knob in position on height adjuster. 2. Firmly push knob on until retainers engage. 3. Reinstall turning loop clam shell cover. 4. Verify seat belt operation. Make sure it moves through loop without binding. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > NHTSA04V047000 > Feb > 04 > Recall 04V047000: Seat Belt Retractor Defect Seat Belt Retractor: Recalls Recall 04V047000: Seat Belt Retractor Defect Make / Models : Model/Build Years: Chrysler / Town & Country 2005 Dodge / Caravan 2005 Dodge / Grand Caravan 2005 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID Number : 04V047000 Recall Date : FEB 03, 2004 COMPONENT: Seat Belts:Front Retractor Potential Number Of Units Affected : 3200 SUMMARY: After performing the NCAP test, it was discovered that on certain minivans equipped without the available "Stow n' Go" seating option, the right front seat belt retractor assembly may have been improperly assembled. CONSEQUENCE: As a result, the seat belt may not properly restrain the occupant during certain crash conditions, which can increase the risk of injury. REMEDY: Dealers will inspect the retractor assemblies and any seat belt assembly that does not have the stake will be replaced. Owner notification began on February 23, 2004. Owners should contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler Recall NO. D04. Customers can also contact The National Highway Traffic Safety Administration Auto Safety Hotline at 1-888-Dash-2-dot (1-888-327-4236). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > D04 > Feb > 04 > Recall - Right Front Seat Belt Retractor Inspection Technical Service Bulletin # D04 Date: 040201 Recall - Right Front Seat Belt Retractor Inspection February 2004 Dealer Service Instructions for: Safety Recall No. D04 Right Front Seat Belt Retractor Models 2005 (RS) Chrysler Town & Country and Dodge Caravan/Grand Caravan NOTE: This recall applies only to the above vehicles NOT EQUIPPED with "Stow ' Go" seating (Sales Code CYC) built at the: > A Louis South Assembly Plant ("B" in the 11th" VIN position) through January 15, 2004 (MDH 011S22). > Windsor Assembly Plant ("R" in the 11th VIN position) through January 16, 2004 (MDH O11605). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The right (passenger side) front seat belt retractor assembly on about 3,200 of the above vehicles may have been improperly assembled. As a result, the seat belt may not properly restrain the occupant, which increases the risk of injury during certain crash conditions. Repair The right front seat belt retractor assembly must be inspected. Assemblies that were not properly assembled must be replaced. Alternate Transportation Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that seat belt retractor replacement is required and the vehicle must be held overnight. Parts Information Due to the small number of involved vehicles expected to require seat belt retractor replacement, no parts will be distributed initially. Seat belt retractors should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require seat belt retractor replacement. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System or on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > D04 > Feb > 04 > Recall - Right Front Seat Belt Retractor Inspection > Page 7977 Use one of the labor operation numbers and time allowances shown. Add the cost of the retractor assembly (if necessary) plus applicable dealer allowance to your claim. Parts Return Removed seat belt retractor assemblies must be returned to the Warranty Material Return Center. NOTE: See the Warranty Administration Manual, Recall Claim Processing and Material Return Sections, for complete recall claim processing instructions. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle Lists, Global Recall System, Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure NOTE: Only seat belt retractor assemblies that missed a staking operation, as determined by the inspection below, require replacement. Very few vehicles are expected to require seat belt retractor replacement. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > D04 > Feb > 04 > Recall - Right Front Seat Belt Retractor Inspection > Page 7978 1. Move the front right passenger seat to the full forward position. 2. Remove the front and side door sill trim. 3. Slide the lower seat belt cover rearward to expose the floor anchor bolt. 4. Remove the lower seat belt anchor bolt from the floor anchor. 5. Remove the sliding door switch from the lower B-pillar trim cover (if equipped) (Figure 1). 6. Disengage the hidden clips and remove the lower B-pillar trim cover (Figure 1). 7. Carefully extract the webbing fully from the seat belt retractor. 8. Using your fingers, turn the retractor webbing spool about another 1/4 turn to expose the recessed area of the spool (Figure 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > D04 > Feb > 04 > Recall - Right Front Seat Belt Retractor Inspection > Page 7979 9. Inspect the circular recess at the front (left) end of the spool recess for the presence of a stake mark (Figure 2). > If there is NO stake mark in the circular recess area (metal is smooth with no indentation), the seat belt retractor must be replaced. Continue with Step 10. > If a stake mark is visible in the circular recess area (conical indentation in circular area), the seat belt retractor does NOT require replacement. Continue with Step 20. 10. Remove the shoulder belt turning loop from the height adjuster. 11. Remove the shoulder belt bezel from the upper B-pillar trim cover (Figure 1). 12. Remove the screw from the bottom center of the upper B-pillar trim cover and then loosen the bottom of the upper cover. 13. Disconnect the lower trim cover seat belt bezel (Figure 1) and then route the seat belt through the openings in the upper and lower B-pillar trim covers. 14. Remove the seat belt retractor attaching bolt. 15. Remove the seat belt retractor assembly from the vehicle and discard it. 16. Install the new seat belt retractor assembly onto the B-pillar. 17. Install the seat belt retractor attaching bolt. Tighten the bolt to 29 ft-lbs (39 N.m). 18. Route the seat belt through the lower and upper B-pillar trim covers and web guide. 19. Install the lower trim cover seat belt bezel (Figure 1). 20. Engage the hidden clips to secure the upper B-pillar trim cover and install the upper cover screw (Figure 1). Tighten the screw securely. 21. Install the upper B-pillar trim cover bezel (Figure 1). 22. Install the shoulder belt turning loop onto the height adjuster. Tighten the turning loop bolt to 29 ft-lbs (39 N.m). 23. Place the lower B-pillar trim cover into position on the B-pillar (Figure 1) 24. Engage the hidden clips to secure the lower trim cover to the B-pillar (Figure 1). 25. Install the power door switch into the lower B-pillar trim cover (if equipped) (Figure 1). 26. Place the lower seat belt anchor in position on the vehicle floor so that the webbing is pointed rearward and slightly outboard. 27. Install the lower seat belt anchor bolt. Tighten the anchor bolt to 29 ft-lbs (39 N.m). 28. Install the front and sliding door sill trim. 29. Return the front passenger seat to its original position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > Recalls for Seat Belt Retractor: > D04 > Feb > 04 > Recall - Right Front Seat Belt Retractor Inspection > Page 7980 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > NHTSA04V047000 > Feb > 04 > Recall 04V047000: Seat Belt Retractor Defect Seat Belt Retractor: All Technical Service Bulletins Recall 04V047000: Seat Belt Retractor Defect Make / Models : Model/Build Years: Chrysler / Town & Country 2005 Dodge / Caravan 2005 Dodge / Grand Caravan 2005 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID Number : 04V047000 Recall Date : FEB 03, 2004 COMPONENT: Seat Belts:Front Retractor Potential Number Of Units Affected : 3200 SUMMARY: After performing the NCAP test, it was discovered that on certain minivans equipped without the available "Stow n' Go" seating option, the right front seat belt retractor assembly may have been improperly assembled. CONSEQUENCE: As a result, the seat belt may not properly restrain the occupant during certain crash conditions, which can increase the risk of injury. REMEDY: Dealers will inspect the retractor assemblies and any seat belt assembly that does not have the stake will be replaced. Owner notification began on February 23, 2004. Owners should contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler Recall NO. D04. Customers can also contact The National Highway Traffic Safety Administration Auto Safety Hotline at 1-888-Dash-2-dot (1-888-327-4236). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > D04 > Feb > 04 > Recall - Right Front Seat Belt Retractor Inspection Technical Service Bulletin # D04 Date: 040201 Recall - Right Front Seat Belt Retractor Inspection February 2004 Dealer Service Instructions for: Safety Recall No. D04 Right Front Seat Belt Retractor Models 2005 (RS) Chrysler Town & Country and Dodge Caravan/Grand Caravan NOTE: This recall applies only to the above vehicles NOT EQUIPPED with "Stow ' Go" seating (Sales Code CYC) built at the: > A Louis South Assembly Plant ("B" in the 11th" VIN position) through January 15, 2004 (MDH 011S22). > Windsor Assembly Plant ("R" in the 11th VIN position) through January 16, 2004 (MDH O11605). IMPORTANT: Many of the vehicles within the above build period have already been inspected or repaired and, therefore, have been excluded from this recall. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to stop sale and complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The right (passenger side) front seat belt retractor assembly on about 3,200 of the above vehicles may have been improperly assembled. As a result, the seat belt may not properly restrain the occupant, which increases the risk of injury during certain crash conditions. Repair The right front seat belt retractor assembly must be inspected. Assemblies that were not properly assembled must be replaced. Alternate Transportation Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if inspection determines that seat belt retractor replacement is required and the vehicle must be held overnight. Parts Information Due to the small number of involved vehicles expected to require seat belt retractor replacement, no parts will be distributed initially. Seat belt retractors should be ordered only after inspection determines that replacement is required. Very few vehicles are expected to require seat belt retractor replacement. Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DIAL System or on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > D04 > Feb > 04 > Recall - Right Front Seat Belt Retractor Inspection > Page 7990 Use one of the labor operation numbers and time allowances shown. Add the cost of the retractor assembly (if necessary) plus applicable dealer allowance to your claim. Parts Return Removed seat belt retractor assemblies must be returned to the Warranty Material Return Center. NOTE: See the Warranty Administration Manual, Recall Claim Processing and Material Return Sections, for complete recall claim processing instructions. Dealer Notification and Vehicle List All dealers will receive a copy of this dealer recall notification letter by DMAIL and by first class mail. Two additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this recall in the near future. Vehicle Lists, Global Recall System, Follow up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed a copy of their vehicle (VIN) list with the dealer recall notification letter. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are identified on the form for owner or dealer reference as needed. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation Service Procedure NOTE: Only seat belt retractor assemblies that missed a staking operation, as determined by the inspection below, require replacement. Very few vehicles are expected to require seat belt retractor replacement. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > D04 > Feb > 04 > Recall - Right Front Seat Belt Retractor Inspection > Page 7991 1. Move the front right passenger seat to the full forward position. 2. Remove the front and side door sill trim. 3. Slide the lower seat belt cover rearward to expose the floor anchor bolt. 4. Remove the lower seat belt anchor bolt from the floor anchor. 5. Remove the sliding door switch from the lower B-pillar trim cover (if equipped) (Figure 1). 6. Disengage the hidden clips and remove the lower B-pillar trim cover (Figure 1). 7. Carefully extract the webbing fully from the seat belt retractor. 8. Using your fingers, turn the retractor webbing spool about another 1/4 turn to expose the recessed area of the spool (Figure 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > D04 > Feb > 04 > Recall - Right Front Seat Belt Retractor Inspection > Page 7992 9. Inspect the circular recess at the front (left) end of the spool recess for the presence of a stake mark (Figure 2). > If there is NO stake mark in the circular recess area (metal is smooth with no indentation), the seat belt retractor must be replaced. Continue with Step 10. > If a stake mark is visible in the circular recess area (conical indentation in circular area), the seat belt retractor does NOT require replacement. Continue with Step 20. 10. Remove the shoulder belt turning loop from the height adjuster. 11. Remove the shoulder belt bezel from the upper B-pillar trim cover (Figure 1). 12. Remove the screw from the bottom center of the upper B-pillar trim cover and then loosen the bottom of the upper cover. 13. Disconnect the lower trim cover seat belt bezel (Figure 1) and then route the seat belt through the openings in the upper and lower B-pillar trim covers. 14. Remove the seat belt retractor attaching bolt. 15. Remove the seat belt retractor assembly from the vehicle and discard it. 16. Install the new seat belt retractor assembly onto the B-pillar. 17. Install the seat belt retractor attaching bolt. Tighten the bolt to 29 ft-lbs (39 N.m). 18. Route the seat belt through the lower and upper B-pillar trim covers and web guide. 19. Install the lower trim cover seat belt bezel (Figure 1). 20. Engage the hidden clips to secure the upper B-pillar trim cover and install the upper cover screw (Figure 1). Tighten the screw securely. 21. Install the upper B-pillar trim cover bezel (Figure 1). 22. Install the shoulder belt turning loop onto the height adjuster. Tighten the turning loop bolt to 29 ft-lbs (39 N.m). 23. Place the lower B-pillar trim cover into position on the B-pillar (Figure 1) 24. Engage the hidden clips to secure the lower trim cover to the B-pillar (Figure 1). 25. Install the power door switch into the lower B-pillar trim cover (if equipped) (Figure 1). 26. Place the lower seat belt anchor in position on the vehicle floor so that the webbing is pointed rearward and slightly outboard. 27. Install the lower seat belt anchor bolt. Tighten the anchor bolt to 29 ft-lbs (39 N.m). 28. Install the front and sliding door sill trim. 29. Return the front passenger seat to its original position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > D04 > Feb > 04 > Recall - Right Front Seat Belt Retractor Inspection > Page 7993 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front Seat Belt Retractor: Service and Repair Front Seat Belt & Retractor - Front Outboard REMOVAL 1. Open door. 2. Move seat all the way forward. 3. Open hood. 4. Disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG SYSTEM OR COMPONENT SERVICE. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, PERSONAL INJURY OR DEATH. Seat Belt - Outboard Front 5. Remove shoulder harness height adjuster knob by pulling it straight away from adjuster. 6. Remove cover from seat belt turning loop. 7. Remove bolt attaching turning loop to shoulder belt height adjuster. 8. Remove upper B-pillar trim cover. NOTE: If equipped with the Occupant Classification System (OCS), there is a Belt Tension Sensor located on the lower seat belt anchor on the passenger front seat belt. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 7996 Belt Tension Sensor/Lower Seat Belt Anchor 9. Remove the lower seat belt anchor bolt. 10. Disconnect the electrical connector if equipped with OCS. 11. Remove front door sill plate. 12. Remove sliding door sill plate. 13. Remove lower B-pillar trim cover. 14. Disconnect the seat belt retractor electrical connector. 15. Remove seat belt retractor attaching bolt. 16. Remove the seat belt and retractor from vehicle. INSTALLATION WARNING: INSPECT THE CONDITION OF THE SHOULDER BELT AND LAP BELT. REPLACE ANY BELT THAT IS CUT, FRAYED, TORN, OR DAMAGED IN ANY WAY. ALSO, REPLACE THE SHOULDER BELT IF THE RETRACTOR IS EITHER DAMAGED OR INOPERATIVE. 1. Place seat belt and retractor into position. 2. Install bolt attaching seat belt retractor to B-pillar. Torque bolt to 39 Nm (29 ft. lbs.). 3. Connect the seat belt retractor electrical connector. 4. Install the lower B-pillar trim cover. 5. Install the sliding door sill plate. 6. Install the front door sill plate. 7. Install the lower seat belt anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). NOTE: If equipped with the Occupant Classification System (OCS), there is a Belt Tension Sensor located on the lower seat belt anchor on the passenger front seat belt. 8. Connect the belt tension sensor connector (if equipped with OCS). 9. Install the upper B-pillar trim cover. 10. Install the bolt attaching turning loop to shoulder belt height adjuster. Torque bolt to 39 Nm (29 ft. lbs.). 11. Install the cover to the seat belt turning loop. 12. Install the shoulder harness height adjuster knob by pushing it straight onto the adjuster. 13. Move seat back to approximate customer position. WARNING: - IF EQUIPPED WITH THE OCS, DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. - IF EQUIPPED WITH THE OCS, FOLLOWING SUCCESSFUL COMPLETION OF THE AIRBAG SYSTEM TEST PROCEDURE, THE OCCUPANT CLASSIFICATION SYSTEM VERIFICATION TEST MUST BE DONE USING A SCAN TOOL AND THE APPROPRIATE DIAGNOSTIC INFORMATION. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 7997 14. Verify vehicle and system operation. 15. Close hood. Seat Belt & Retractor-First Row-Outboard REMOVAL 1. Remove first and second row seats. 2. Remove first row seat belt lower anchor bolt. 3. Remove first row seat belt upper turning loop anchor bolt. 4. Remove liftgate sill plate. Remove second seat lower anchor bolt. 5. Remove upper liftgate trim. 6. Remove second seat lower anchor bolt. 7. Remove second seat upper turning loop anchor bolt. 8. Remove D-pillar trim cover. 9. Disconnect speaker connector. The left side has the speaker mounted in the D-pillar trim cover and the right side will have the speaker mounted in the rear of the quarter trim panel, but the connector is accessible from the rear after the D-pillar trim is removed. 10. Remove quarter trim bolster. 11. Remove quarter trim panel screws. 12. Remove quarter trim panel. 13. Remove first row seat belt and retractor retaining bolt. 14. Remove first row seat belt and retractor from vehicle. INSTALLATION 1. Install first row seat belt and retractor. Torque bolt to 39 Nm (29 ft. lbs.). 2. Install quarter trim panel. 3. Install quarter trim panel screws. 4. Install quarter trim bolster. 5. Connect speaker connector. The left side has the speaker mounted in the D-pillar trim cover and the right side will have the speaker mounted in the rear of the quarter trim panel, but the connector is accessible from the rear after the D-pillar trim is removed. 6. Install D-pillar trim cover. 7. Install second seat belt lower anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 8. Install second seat belt upper turning loop anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 9. Install upper liftgate trim. 10. Install liftgate sill plate. 11. Install first row seat belt upper turning loop anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 12. Install first row seat belt lower anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 13. Install first and second row seats. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 7998 Seat Belt Retractor: Service and Repair Second Row Seat Belt & Retractor-Second Row-Left Outboard REMOVAL 1. Remove first and second row seats. 2. Remove first row seat belt lower anchor bolt. 3. Remove first row seat belt upper anchor bolt. 4. Remove liftgate sill plate. 5. Remove upper liftgate trim. 6. Remove second seat belt lower anchor bolt. 7. Remove second seat belt upper anchor bolt. 8. Remove D-pillar trim cover. 9. Disconnect speaker connector. The left side has the speaker mounted in the D-pillar trim cover and the right side will have the speaker mounted in the rear of the quarter trim panel, but the connector is accessible from the rear after the D-pillar trim is removed. 10. Remove quarter trim bolster. 11. Remove quarter trim panel screws. 12. Remove quarter trim panel. 13. Remove retractor retaining bolt. 14. Remove second row seat belt and retractor from vehicle. INSTALLATION 1. Install second row seat belt and retractor. Torque bolt to 39 Nm (29 ft. lbs.). 2. Install quarter trim panel. 3. Install quarter trim panel screws. 4. Install quarter trim bolster. 5. Connect speaker connector. The left side has the speaker mounted in the D-pillar trim cover and the right side will have the speaker mounted in the rear of the quarter trim panel, but the connector is accessible from the rear after the D-pillar trim is removed. 6. Install D-pillar trim cover. 7. Install second seat belt lower anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 8. Install second seat belt upper turning loop anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 9. Install upper liftgate trim. 10. Install liftgate sill plate. 11. Install first row seat belt upper turning loop anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 12. Install first row seat belt lower anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 13. Install first and second row seats. Seat Belt & Retractor-Second Row-Right Outboard REMOVAL 1. Remove first and second row seats. 2. Remove first row seat belt lower anchor bolt. 3. Remove first row seat belt upper anchor bolt. 4. Remove liftgate sill plate. 5. Remove upper liftgate trim. 6. Remove second seat belt lower anchor bolt. 7. Remove second seat belt upper anchor bolt. 8. Remove D-pillar trim cover. 9. Disconnect speaker connector. The left side has the speaker mounted in the D-pillar trim cover and the right side will have the speaker mounted in the rear of the quarter trim panel, but the connector is accessible from the rear after the D-pillar trim is removed. 10. Remove quarter trim bolster. 11. Remove quarter trim panel screws. 12. Remove quarter trim panel. 13. Remove retractor retaining bolt. 14. Remove second row seat belt and retractor. INSTALLATION 1. Install second row seat belt and retractor. Torque bolt to 39 Nm (29 ft. lbs.). 2. Install quarter trim panel. 3. Install quarter trim panel screws. 4. Install quarter trim bolster. 5. Connect speaker connector. The left side has the speaker mounted in the D-pillar trim cover and the right side will have the speaker mounted in the rear of the quarter trim panel, but the connector is accessible from the rear after the D-pillar trim is removed. 6. Install D-pillar trim cover. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 7999 7. Install second seat belt lower anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 8. Install second seat belt upper turning loop anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 9. Install upper liftgate trim. 10. Install liftgate sill plate. 11. Install first row seat belt upper turning loop anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 12. Install first row seat belt lower anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 13. Install first and second row seats. Seat Belt & Retractor-Second Row-Right Outboard With Rear HVAC-LWB REMOVAL 1. Remove first and second row seats. 2. Remove first row seat belt lower anchor bolt. 3. Remove first row seat belt upper anchor bolt. 4. Remove liftgate sill plate. 5. Remove upper liftgate trim. 6. Remove second seat belt lower anchor bolt. 7. Remove second seat belt upper anchor bolt. 8. Remove D-pillar trim cover. 9. Disconnect speaker connector. The left side has the speaker mounted in the D-pillar trim cover and the right side will have the speaker mounted in the rear of the quarter trim panel, but the connector is accessible from the rear after the D-pillar trim is removed. 10. Remove quarter trim bolster. 11. Remove quarter trim panel screws. 12. Remove quarter trim panel. 13. Loosen HVAC unit enough to gain access to seat belt retractor fasteners. Trim Panel Mounting Bracket a. Remove bracket around HVAC unit. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 8000 Lower Heater Duct b. Remove air duct. Rear HVAC Mounting c. Remove fasteners attaching HVAC unit to inner quarter panel. d. Gently pry out on rear HVAC unit to gain access to the seat belt and retractor. 14. Remove bolts attaching seat belt guide loop to inner quarter panel. 15. Pull outward on HVAC unit and remove bolt attaching retractor to inner quarter panel. 16. Remove second row seat belt and retractor from vehicle. INSTALLATION 1. Position second row seat belt and retractor to vehicle. 2. Pull outward on HVAC unit and install bolt attaching retractor to inner quarter panel. Torque bolt to 39 Nm (29 ft. lbs.). 3. Install bolts attaching seat belt guide loop to inner quarter panel. 4. Install fasteners attaching HVAC unit to inner quarter panel. 5. Install air duct. 6. Install trim panel retaining bracket around HVAC unit. 7. Install quarter trim panel. 8. Install quarter trim panel screws. 9. Install quarter trim bolster. 10. Connect speaker connector. The left side has the speaker mounted in the D-pillar trim cover and the right side will have the speaker mounted in the rear of the quarter trim panel, but the connector is accessible from the rear after the D-pillar trim is removed. 11. Install D-pillar trim cover. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Front > Page 8001 12. Install second seat belt lower anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 13. Install second seat belt upper turning loop anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 14. Install upper liftgate trim. 15. Install liftgate sill plate. 16. Install first row seat belt upper turning loop anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 17. Install first row seat belt lower anchor bolt. Torque bolt to 39 Nm (29 ft. lbs.). 18. Install first and second row seats. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tension Sensor > Component Information > Description and Operation Seat Belt Tension Sensor: Description and Operation Belt Tension Sensor Belt Tension Sensor Location Vehicles equipped with the Occupant Classification System (OCS) include a belt tension sensor. This sensor is integral to the passenger side front seat belt lower anchor which is secured to the lower B-pillar, on the passenger side. The belt tension sensor consists of a molded plastic housing, a metal seat belt anchor loop, and a short pigtail wire. The electronic circuitry of the belt tension sensor is concealed and protected within the molded plastic housing. The belt tension sensor cannot be repaired and, if faulty or damaged, the entire passenger side front seat belt and retractor unit must be replaced. The belt tension sensor is designed to sense the relative cinch load applied to the passenger side front seat belt, which provides a logic input to the microprocessor of the Occupant Classification Module (OCM). When a load is applied to the seat belt, the changes in the load are measured by the belt tension sensor through the seat belt lower anchor. As the load changes, the circuitry of the belt tension sensor changes the output voltage of the sensor. The belt tension sensor receives a nominal five volts and a ground from the OCM. The OCM then monitors the belt tension sensor output voltage. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tension Sensor > Component Information > Description and Operation > Page 8005 WARNING: DO NOT CONNECT THE BATTERY BEFORE PERFORMING THE OCS VERIFICATION TEST USING THE SCAN TOOL AND THE APPROPRIATE DIAGNOSTIC INFORMATION. PERSONAL INJURY OR DEATH MAY OCCUR. For further diagnosis and testing of the belt tension sensor, the OCM, and related occupant classification system components, use a scan tool and the appropriate diagnostic information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations Seat Belt Tensioner: Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Page 8009 Seat Belt Tensioner: Diagrams Belt Tension Sensor Driver Seat Belt Tensioner Passenge Seat Belt Tensioner Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Page 8010 Seat Belt Tensioner: Description and Operation The seat belt system incorporates Seat Belt Tensioners. The tensioner is designed to hold the occupant in their respective seat by retracting the seat belt up to four inches. They are integral to the front seat belt buckles and cannot be serviced. If found defective they must be replaced. After an airbag deployment, the tensioner must be replaced. Seat Belt Tensioners supplement the dual front air-bag system. The seat belt tensioners are integral to the front seat belt buckles, which are secured to the seat cushion frame on the inboard side. The seat belt tensioners are controlled by the Occupant Restraint Controller (ORC) and are connected to the vehicle electrical system through the body wire harness. The seat belt tensioners cannot be repaired and, if faulty or damaged, the entire front seat belt buckle must be replaced. The seat belt tensioners are not intended for reuse and must be replaced following any front airbag deployment. WARNING: WHEN THE FRONT AIRBAG IS DEPLOYED, THE TENSIONER WILL HAVE DEPLOYED ALSO AND SHOULD BE REPLACED. FAILURE TO DO SO COULD RESULT IN OCCUPANT PERSONAL INJURY OR DEATH. The seat belt tensioners are deployed by a signal generated by the Occupant Restraint Controller (ORC) through the driver or passenger seat belt tensioner line 1 and line 2 (or squib) circuits. When the ORC sends the proper electrical signal to the tensioners, the electrical energy generates enough heat to initiate a small pyrotechnic gas generator. Removing excess slack from the front seat belts not only keeps the occupants properly positioned for an airbag deployment following a frontal impact of the vehicle, but also helps to reduce injuries that the occupants of the front seat might experience in these situations as a result of a harmful contact with the steering wheel, steering column, instrument panel and/or windshield. The ORC monitors the condition of the seat belt tensioners through circuit resistance, and will illuminate the airbag indicator in the ElectroMechanical Instrument Cluster (EMIC) and store a Diagnostic Trouble Code (DTC) for any fault that is detected. For proper diagnosis of the seat belt tensioners, use a scan tool and the appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams Passenger Seat Weight Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Diagrams > Page 8014 Seat Sensor/Switch: Description and Operation Seat Weight Bladder And Pressure Sensor - Typical Vehicles equipped with the Occupant Classification System (OCS) have a seat weight bladder and pressure sensor unit that is integral to the passenger front seat cushion. The bladder is sandwiched between the seat cushion pan and seat cushion foam. The bladder consists of two rectangular sheets of an elastomeric material and a molded plastic elbow fitting. The two sheets of material are sealed together around their perimeter and heat staked to each other at numerous regular points within their field. The elbow fitting is sealed to a small round hole in the lower surface of the bladder and is pointed downward where it passes through a clearance hole in the insulator pad and extends to just below the seat cushion. The bladder is then filled with a silicone fluid to become a pliable, quilted membrane. Under the seat cushion a short tube is securely clamped at one end to the bladder nipple, and at the other end to a nipple on the electronic pressure sensor. The sensor housing features an integral mount that snaps over a tab integral to the stamped steel Occupant Classification Module (OCM) mounting bracket welded to the underside of the passenger front seat cushion frame. The seat weight bladder and pressure sensor cannot be adjusted or repaired. The components of the passenger front seat cushion of a vehicle equipped with the OCS including the cushion frame, seat weight bladder and pressure sensor, seat cushion foam, wire harness and the OCM are serviced only as a factory-calibrated, assembled and tamper-evident unit. Only the OCM and the seat cushion trim are available for separate service replacement. Once a service replacement package has been installed in a vehicle, the OCM can thereafter be serviced only by replacing the entire passenger front seat cushion unit with another complete service replacement package. The seat weight bladder and pressure sensor unit is designed to sense the relative weight of a load applied to the passenger front seat cushion, which provides a logic input to the microprocessor of the Occupant Classification Module (OCM). When a load is applied to the seat cushion, fluid within the bladder becomes pressurized. These changes in bladder fluid pressure are measured by the pressure sensor under the seat cushion through the bladder tube. As the pressure within the bladder changes, the circuitry of the pressure sensor changes the output voltage of the sensor. The pressure sensor receives a nominal five volts and a ground through hard wired circuits from the OCM. The OCM then monitors the pressure sensor output voltage on the Programmable Communication Interface (PCI) data bus circuit. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement Technical Service Bulletin # J38 Date: 100420 Campaign - Front Air Bag Sensor Replacement April 2010 Dealer Service Instructions for: Customer Satisfaction Notification J38 Supplemental Front Airbag Sensors Models 2005-2006 (RS) Dodge Caravan, Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles built from January 19, 2005 through April 5, 2006 (MDH 011900 through 040500). IMPORTANT: Many of the vehicles within the above build period have already been repaired according to our warranty records, and therefore, have been excluded from this notification. Only the above vehicles originally sold or currently registered in certain states are involved. See the "Owner Notification and Service Scheduling" section for a list of states involved in this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The supplemental front airbag sensors on about 310,000 of the above vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Repair The right and left supplemental front airbag sensors must be replaced and the sensor wiring harness connectors must be inspected and replaced, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8024 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8025 Parts Information Special Tools The following special tools may be required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8026 Use the labor operation numbers and time allowances as shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicableable. Only vehicles originally sold or currently registered in the following states are involved in this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8027 To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure A. Supplemental Front Airbag Sensor Replacement 1. Lower the driver's window completely. 2. Open the hood. 3. Disconnect and isolate the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Raise the vehicle on a suitable hoist. 5. Disconnect the wiring harness connector to the right and left supplemental front airbag sensor. The sensors are located on the outside of the right and left frame rails at the radiator lower crossmember (Figure 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8028 6. Remove the right and left supplemental front airbag sensors and discard the sensors and retaining bolts. CAUTION: If the retaining bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose from the radiator lower crossmember. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensor retaining bolts, continue with Step 9. 7. Use the following procedure, if required, to replace a spun riv-nut: a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps. b. Remove the four screws (two each side) that secure the left and right wheelhouse splash shield to the front fascia. c. Remove the right and left side fascia-to-fender bolts. d. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. e. Partially lower the vehicle. f. Remove the right and left fascia bolts from the upper radiator crossmember (Figure 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8029 g. Pull the wheelhouse shield back from the front fascia and remove the right and left nuts holding the front fascia to the front lip of the fender (Figure 3). h. Carefully remove the front fascia and set it aside. CAUTION: Be careful not to scratch the painted surfaces of the front fascia and front fenders. i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard. j. Using a cut-off wheel, remove the head of the airbag sensor mounting bolt. k. Remove and discard the supplemental front airbag sensor bushing. l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool. NOTE: Be sure to completely remove the riv-nut from the lower radiator crossmember. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8030 n. Pre-assemble the new riv-nut by installing the installation nut and the riv-nut onto the installation bolt as shown in Figure 4. o. Insert the new riv-nut-bolt/nut assembly into the original riv-nut hole in the lower radiator crossmember. p. Using a 10mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5). q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut. r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely). 8. For vehicles that had the front fascia removed, use the following procedure to install the front fascia: a. Position the front fascia onto the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8031 b. Install the right and left upper fascia bolts finger tight (Figure 6). c. Install the right and left nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m). d. Install and tighten the two fascia-to-fender bolts. e. Install the four screws (two on each side) that secure the right and left wheelhouse shield to the front fascia. f. Using new push pins if necessary, install the air dam to the lower radiator crossmember. g. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps. h. Continue with Step 9. 9. Inspect the right and left supplemental front airbag sensor wiring connectors. > If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B. Airbag Sensor Harness Connector Replacement. > If there is no corrosion on either terminal of the harness connectors, continue with Section C. Supplemental Front Airbag Sensor Installation. B. Airbag Sensor Harness Connector(s) Replacement NOTE: Only those harness connector(s) that exhibit terminal corrosion, as described in Section A, require replacement. 1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector. 2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness. 3. Remove 1/2 inch (13 mm) of insulation from each wire. 4. Cut the new harness connector wires so that the final length is equal to the old harness. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8032 5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire. 6. Slide one piece of heat shrink tubing onto each of the harness connector wires. 7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just enough to hold the splice band in place. 8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows: > For the right (passenger side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the purple (w/blue tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the white (w/blue tracer) wire on the body wiring harness. > For the left (driver's side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the blue (w/purple tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the blue (w/white tracer) wire on the body wiring harness. CAUTION: Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band. 10. Crimp the splice band and wires together by squeezing the crimping tool handles. NOTE: The tool will release once the proper crimping force has been achieved. 11. Solder the connection together using only rosin core type solder. CAUTION: DO NOT use acid core solder. 12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing. CAUTION: Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure. 13. Continue with Section C. Supplemental Front Airbag Sensor Installation. C. Supplemental Front Airbag Sensor Installation 1. Clean the supplemental front airbag sensor mounting surface for both sensors. 2. Install the new supplemental front airbag sensors using the fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091. NOTE: Use the bolts with a blue thread locker patch on the threads. Discard the pointed self tapping screws and flat washers. They will not be used in this repair procedure. 3. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. 4. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8033 5. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector (Figure 7). NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor wiring harness connector. 6. Connect the wiring harness connectors to the right and left supplemental front airbag sensors. 7. Lower the vehicle from the hoist. 8. For vehicles that had the Fascia removed, tighten the upper fascia bolts to 50 in. lbs. (5 N.m). 9. Connect the negative battery cable to the battery. 10. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "RUN" position. Wait 10 seconds: > If the airbag warning light is not illuminated, the repair has been completed. No further action is required, return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 11 to clear the Diagnostic Trouble Codes (DTC's). 11. Use the following procedure to clear DTC's: a. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. b. Turn the ignition key to the "RUN" position. c. Press the "YES" button after the DRBIII powers up. d. Select "DRBIII STANDALONE" and press "ENTER". e. Select "1998-2007 DIAGNOSTICS" and press "ENTER". f. Select "ALL" and press "ENTER". g. Select "PASSIVE RESTRAINT" and press "ENTER". h. Select "AIRBAG" and press "ENTER". i. Select "READ DTC's" and press "ENTER". j. Select "STORED" and press "ENTER". k. Press the "PAGE BACK" button and follow the screen prompts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8034 l. Disconnect and remove the DRBIII from the vehicle and return the vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement Technical Service Bulletin # G09 Date: 070601 Recall - Front Air Bag Impact Sensor Replacement June 2007 Dealer Service Instructions for: Customer Satisfaction Notification G09 Supplemental Front Airbag Sensors Models 2005 (RS) Dodge Caravan, Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles built at the Windsor Assembly plant ("R" in the 11th VIN position) through February 3, 2005 (MDH 020323) and the St. Louis Assembly plant ("B" in the 11th VIN position) through January 19, 2005 (MDH 011923). IMPORTANT: Many of the vehicles within the above build period have already been repaired according to our warranty records, and therefore, have been excluded from this notification. Only the above vehicles originally sold or currently registered in certain states are involved. See the "Owner Notification and Service Scheduling" section for a list of states involved in this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair service on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The supplemental front airbag sensors on about 263,000 of the above vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Repair The right and left supplemental front airbag sensors must be replaced and the sensor harness connectors must be inspected and replaced, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8039 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8040 Parts Information Special Tools The special tools may be required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record repair service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8041 Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Attached to each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Only vehicles originally sold or currently registered in the following states are involved in this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Supplemental Front Airbag Sensor Replacement 1. Lower the driver¡C■s window completely. 2. Open the hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8042 3. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Raise the vehicle on a suitable hoist. 5. Disconnect the harness connector to the right and left supplemental front airbag sensor (Figure 1). 6. Remove the right and left supplemental front airbag sensors and discard the bolts and sensors. NOTE: There are two types of bolts used to fasten the sensors to the radiator crossmember; an M7 self tapping bolt or an M6 bolt used with a riv-nut. If the bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensors, continue with Step 8. 7. Replaced a spun riv-nut as follows: NOTE: The following procedure is applicable for vehicle built at the Windsor Assembly Plant after May 24, 2004 or the St. Louis Assembly Plant after June 28, 2004. Very few vehicles are expected to require riv-nut replacement. a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps. b. Remove the two screws that secure the left and right wheelhouse splash shield to the front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8043 c Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. d. Partially lower the vehicle. e. Remove the right and left fascia upper bolts from the upper radiator crossmember (Figure 2). f. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Figure 3) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8044 g. Remove the two vertical screws holding the front fascia to the front fender. h. Carefully remove the front fascia and set it aside. CAUTION: Be careful not to scratch the painted surfaces of the front fascia and the front fenders. i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard. j. Using a cut-off wheel, cut off the head of the airbag sensor mounting bolt. k. Remove and discard the supplemental front airbag sensor bushing. l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool. NOTE: Be sure to completely remove the riv-nut from the lower radiator crossmember. n. Pre-assemble the new riv-nut by installing the M6 nut and the riv-nut onto the M6 bolt as shown in Figure 4. o. Insert the riv-nut-bolt/nut assembly into the body sheet metal hole. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8045 p. Using a 10 mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5). q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut. r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely). s. Clean the supplemental front airbag sensor mounting surface for both sensors. t. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091: > For sensors fastened with self tapping bolts: a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6. b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts. c. Tightening the self tapping bolts to 60 in.lbs. (7 N.m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8046 > For sensors fastened with M6 bolts and riv-nuts: a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). u. Inspect the right and left supplemental front airbag sensor wiring connectors. If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B Harness Connector Replacement. v. Position the front fascia onto the vehicle. w. Install the right and left upper bolts fascia bolts and tighten to 50 in. lbs. (5 N.m). x. Install the right and left horizontal nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m). y. Install and tighten the two vertical screws that secure the front fascia to the front fenders. z. Install the two screws that secure the right and left wheelhouse shield to the front fascia. aa. Using new push pins if necessary, install the air dam to the lower radiator crossmember. ab. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps. ac. Continue with Step 10. 8. Clean the supplemental front airbag sensor mounting surface for both sensors. 9. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091: > For sensors fastened with self tapping bolts: a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6. b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts. c. Tightening the self tapping bolts to 60 in. lbs. (7 N.m). > For sensors fastened with M6 bolts and riv-nuts: a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). 10. Inspect the right and left supplemental front airbag sensor wiring connectors. If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B - Harness Connector Replacement. 11. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector. NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector. 12. Connect harness connectors to the right and left supplemental front airbag sensors. 13. Lower the vehicle. 14. Connect the negative battery cable to the battery. 15. Stand next to the vehicle with the driver¡C■s door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "ON" position. Wait 10 seconds: > If the airbag warning light is not illuminated the repair has been completed. Return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8047 continue with Step 16 to clear the sensor DTC. 16. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. 17. Turn the ignition key to the "ON" position. 18. Press the "YES" button when the DRBIII powers up. 19. Select "DRBIII STANDALONE" and press "ENTER". 20. Select "1997-2007 DIAGNOSTICS" and press "ENTER". 21. Select "ALL" and press "ENTER" 22. Select "PASSIVE RESTRAINT" and press "ENTER". 23. Select "CLEAR DTCS". 24. Disconnect and remove the DRBIII from the vehicle. B. Airbag Sensor Harness Connector Replacement NOTE: Only those harness connectors that exhibit terminal corrosion, as described in Section A, require replacement. 1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector. 2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness. 3. Remove 1/2 inch (13 mm) of insulation from each wire. 4. Cut the new harness connector wires so that the final length is equal to the old harness. 5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire. 6. Slide one piece of heat shrink tubing onto each of the harness connector wires. 7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just the tool just CAUTION: The crimp jaw must be installed in the crimp tool frame as shown in Figure 7. The crimp jaw wire gauge numbers must be on the same side. When installing the crimp jaw into the tool frame, orient the upper die with the arrow pointed "up" and the lower die with the arrow pointed forward. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8048 8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows: > For the right (passenger side) supplemental front airbag sensor, match the new harness connector wire colors to the same color wire on the existing body wire harness. > For the left (driver's side) supplemental front airbag sensor, match the new harness connector wire colors to same tracer (stripe) color wire on the existing body wire harness. CAUTION: Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. warning lamp. 9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band (Figure 8). 10. Crimp the splice band and wires together by squeezing the crimping tool handles. The tool will release once the proper crimping force has been achieved (Figure 8). 11. Solder the connection together using only rosin-core type solder (Figure. 9). CAUTION: DO NOT use acid core solder. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8049 12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Figure 10). CAUTION: Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure. 13. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector. NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector. 14. Connect harness connectors to the right and left supplemental front airbag sensors. 15. For vehicles with the front fascia removed: a. Position the front fascia onto the vehicle. b. Install the right and left upper fascia bolts and tighten to 50 in. lbs. (5 N.m). c. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender. Tighten the nuts to 60 in. lbs. (7 N.m). d. Install and tighten the two vertical screws that secure the front fascia to the front fenders. e. Install the two screws that secure the right and left wheelhouse shield to the front fascia. f. Using new push pins if necessary, securing the air dam to the lower radiator crossmember. g. For vehicles with fog lamps, connect the electrical harness connectors to the right and left fog lamps. 16. Lower the vehicle. 17. Connect the negative battery cable to the battery. 18. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel, and turn the ignition key to the "ON" position. Wait 10 seconds: > If the airbag warning light is not illuminated, the repair has been completed. Return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 19 to clear the sensor DTC. 19. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. 20. Turn the ignition key to the "ON" position. 21. Press the "YES" button when the DRBIII powers up. 22. Select "DRBIII STANDALONE" and press "ENTER". 23. Select "1997-2007 DIAGNOSTICS" and press "ENTER". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8050 24. Select "ALL" and press "ENTER". 25. Select "PASSIVE RESTRAINT" and press "ENTER". 26. Select "CLEAR DTCS". 27. Disconnect and remove the DRBIII from the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Recalls: > NHTSA07V192000 > May > 07 > Recall 07V191000: Air Bag Impact Sensor Replacement Impact Sensor: Recalls Recall 07V191000: Air Bag Impact Sensor Replacement MAKE/MODELS: MODEL/BUILD YEARS: Chrysler/Town & Country 2005 Dodge/Caravan 2005 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V192000 MFR'S REPORT DATE: May 01, 2007 COMPONENT: Air Bags: Frontal: Sensor/Control Module POTENTIAL NUMBER OF UNITS AFFECTED: 270958 SUMMARY: Certain minivans are being recalled that were originally sold in or currently registered in the 27 states plus The District of Columbia that use greater amounts of salt for Winter road deicing. The Up-Front (UF) air bag sensors that contain brass bushings installed in these vehicles may corrode and crack allowing water to enter the sensor. These sensors provide enhanced air bag performance in certain types of frontal crashes. CONSEQUENCE: In one of these crashes, with one or both of the vehicle the vehicle's UF sensors inoperative, the occupants will not benefit from the enhanced air bag protection that these sensors would provide. REMEDY: For vehicles registered in the recall states, dealers will replace the original UF air bag sensors with ones with greater corrosion resistance. Vehicles registered in other states will obtain a lifetime free replacement of any UF sensor that fails. The campaign is expected to begin during July 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler's campaign Nos. G09/X16. DaimlerChrysler has not decided that this is a defect related to motor vehicle safety. However, it has informed NHTSA that it will provide the modifications described above free of charge. Customers also may contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline aT 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set Technical Service Bulletin # 08-020-07 Date: 070713 Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set NUMBER: 08-020-07 GROUP: Electrical DATE: July 13, 2007 SUBJECT: Supplemental Front Air Bag Sensor Replacement (Lifetime Warranty) OVERVIEW: This bulletin involves verifying that a right and/or left front impact supplemental airbag sensor(s) Diagnostic Trouble Code (DTC) exists in the Occupant Restraint Control Module (ORG). If DTC's exist, the right and left supplemental front airbag sensors must be replaced and the sensor harness connectors must be inspected for corrosion and replaced if necessary. NOTE: Technicians performing this procedure for the first time should fully familiarize themselves with the steps and procedures listed in this Service Bulletin before proceeding. MODELS: 2005 (RG) Chrysler Voyager 2005 (RS) Town & Country/Caravan/Voyager NOTE: This bulletin applies to vehicles built at the Windsor Assembly Plant ("R" in the 11th VIN position) through February 3, 2005 (MDH 020323), the St. Louis Assembly plant ("B" in the 11th VIN position) through January 19, 2005 (MDH 011923) or the Styler Assembly plant ("Y" in the 11th VIN position) through January 04, 2005 (MDH 010423). DISCUSSION: The supplemental front airbag sensors may crack under certain conditions and allow water to enter into the sensor(s). These sensors were added to enhance the performance of the vehicles airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. DIAGNOSIS: If the vehicle operator experiences air bag warning lamp illumination with any of the following DTC's; NO RIGHT FRONT IMPACT SENSOR COMMUNICATION / RIGHT FRONT IMPACT SENSOR INTERNAL 1/ NO LEFT FRONT IMPACT SENSOR COMMUNICATION or LEFT FRONT IMPACT SENSOR INTERNAL 1, perform the Repair Procedure. If the air bag warning lamp is on due to other DTC's, this bulletin does not apply. Refer to diagnostic procedures available in DealerCONNECT >>> TechCONNECT under: Diagnostics > 7.2 AIRBAG for further information. NOTE: Vehicles that are included in Customer Satisfaction Notification G09 are not included in this Service Bulletin and must be repaired under the procedures and labor operation numbers listed within G09. Vehicles not included in G09 must use this Service Bulletin for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8060 PARTS REQUIRED: NOTE: Connectors, Self-Tapping Screws and Riv-nuts will be used on an "as needed" basis. SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. NOTE: Vehicles included in this Service Bulletin have a lifetime warranty on supplemental front airbag sensors, mounting hardware and sensor electrical connectors as described in this Service Bulletin. See Warranty Bulletin D-07-19 for details associated with the lifetime warranty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8061 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Lower the driver's side window. 2. Disconnect the Negative Battery Cable. 3. Refer to the detailed removal procedures available in DealerCONNECT >>> TechCONNECT under: Service Information Tab >>> Group 8, Electrical >>> Restraints >>> Impact Sensor >>> Removal. 4. When removing the attaching bolts for the sensor, does any of the bolts spin freely and not come out? (See NOTES below). a. Yes >>> Proceed to Step # 5 b. No >>> Proceed to Step # 22 NOTE: There are 2 types of bolts used to fasten the sensors to the radiator crossmember; a M7 self tapping bolt or a M6 bolt used with a riv-nut. If the bolt spins and cannot be removed, the riv-nut has broken loose. If the riv-nut spins and the bolt cannot be removed, proceed to next step to replace riv-nut(s). If no issue with the riv-nut is found, proceed to Step # 22. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8062 NOTE: The riv-nut procedure is applicable for vehicles built at the Windsor Assembly plant after May 24, 2004 or the St. Louis Assembly plant after June 28, 2004 or the Styler Assembly plant after June 28, 2004. Very few vehicles will require riv-nut replacement. 5. If the vehicle equipped with fog lamps, disconnect electrical harness connectors from both fog lamps. 6. Remove the 2 screws that secure the left and right wheelhouse splash shield to the front fascia. 7. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. 8. Remove the right and left fascia upper bolts from the upper radiator crossmember. (Fig 2) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8063 9. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Fig. 3) 10. Remove 2 vertical screws holding the front fascia to the front fender. 11. Carefully remove the front fascia and set aside. CAUTION: Care should be used not to damage painted surfaces. 12. Break the front air bag sensor using a suitable tool. Remove broken sensor pieces. 13. Using a powered cut-off wheel, remove the head of the sensor mounting bolt. 14. Remove sensor bushing from bolt. 15. Using a powered cut-off wheel, cut the bolt and lip of the riv-nut flush with sheet metal. 16. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. 17. Remove the old riv-nut through the access hole in the crossmember using a magnetic tool. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8064 18. Preassemble the new riv-nut, p/n CBX2G093 by installing the M6 nut, and the riv-nut onto the bolt, as shown in (Fig. 4). 19. Insert the riv-nut and bolt assembly into the original mounting hole. 20. Using a 10 mm crows foot, tighten the installation nut to 9 Nm, (80 in. lb) while holding the installation bolt stationary (Fig. 5). 21. Repeat Step # 12 through Step # 20 for remaining riv-nut(s) that have broken loose and spin freely. 22. Clean the mounting surface for both sensors. 23. Install the new sensors using the appropriate fasteners; Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8065 a. For sensors fastened with self-tapping bolts. Proceed to >>> # 24. b. For sensors fastened with M6 bolts and riv-nuts. Proceed to >>> Step # 26. 24. For self-tapping fastener installation; preassemble both air bag sensors with self-tapping bolts and washers (Fig. 6). 25. Position the sensors on the vehicle and tighten each self-tapping bolt into the mounting hole about 5 turns to cut new threads for the larger M7 bolt. Tighten to 7 Nm, (60 in. lb). Proceed to Step # 27. 26. For M6 bolt and riv-nut fastener installation; hand start both bolts in sensors. Tighten to 7 Nm, (60 in. lb). 27. Inspect the right and left air bag sensor wiring connectors. Is there is any sign of corrosion, (white, green or black), on either terminal of the harness connectors? a. Yes >>> Proceed to Step # 28. b. No >>> Proceed to Step # 39. NOTE: Only replace harness connectors that exhibit terminal corrosion. 28. Cut wire harness 3 in. (75 mm) back from connector. 29. Remove 1 in. (25 mm) of black tape from wire harness going to the vehicle. 30. Strip .5 in. (13 mm) of insulation from each wire. 31. Cut the new sensor connector wire harness p/n CBX2G092 the same length as the removed connector wire harness. 32. Strip .5 in. (13 mm) of insulation from each wire. 33. Slide one piece of heat shrink tubing on each of the wires. 34. Load and center the splice band into cavity "B" of crimp tool # 10042. Close the tool just enough to hold the splice band in place NOTE: First time use of crimp tool #10042 will require the crimp dies to be installed on the crimper frame. Orient the upper die with the arrow pointed up and the lower die with the arrow pointed forward. The numbers on upper die and letters on lower die will be on the same side. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8066 35. Match the new harness connector wires to the existing vehicle harness as follows: a. For the right (passenger side) sensor, match the new harness connector wire colors to the same color wire on the existing vehicle wire harness. b. For the left (driver side) sensor, match the new harness connector wire colors to the same tracer stripe color wire on the existing vehicle wire harness. CAUTION: Ensure wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 36. Insert the matched bare wires through the crimp connector from opposite ends. Crimp the connections using #10042 wire splice crimp tool. 37. Solder the crimped connection using only rosin-core solder. 38. Center heat shrink tubing over the connection and heat with a heat gun until tubing is tight and sealant is witnessed at the ends (Fig 7). CAUTION: Use only the sealant lined heat shrink tube supplied in wiring kit above. Use of electrical tape or non-sealant lined heat shrink tube may cause circuit failure. 39. Apply a small amount of dielectric grease, p/n J81 26688 to the airbag sensor connector end. Using a finger, force the grease into the terminal connections of the airbag sensor connector. 40. Connect the harness connectors to both front airbag sensors. 41. Has the fascia been removed? a. Yes >>> Proceed to Step # 42. b. No >>> Proceed to Step # 49. 42. Position the front fascia onto the vehicle. 43. Install the right and left upper fascia bolts, tighten to 5 Nm (50 in lb). 44. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender and tighten to 7 Nm (60 in lb). 45. Install the two vertical screws that secure the front fascia to the front fenders. 46. Install the two screws that secure the right and left wheelhouse shield to the front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8067 47. Using new push pins, if necessary, securing the air dam to the lower radiator crossmember. 48. Connect the electrical harness connectors to the right and left fog lamps, if equipped. 49. Connect the negative battery cable to the battery. 50. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel, and turn the ignition key to the "ON position. Wait 10 seconds: a. If the airbag warning light is not illuminated, the repair is complete. Proceed to to clear stored DTC's. b. If the airbag warning light is illuminated due to supplemental front airbag sensor faults, switch the ignition key "OFF and Proceed to and clear any DTC's. If the DTC's return and ARE related to the Front Impact Sensor(s), Verify proper wiring connections as described in above. If wiring connections are correct, or if DTC's are related to other components of the supplemental airbag system, refer to the diagnostic information available in DealerCONNECT >>> TechCONNECT under: Diagnostics > 7.2 AIRBAG for further information. 51. Turn the ignition "OFF" and connect the DRBIII(R). NOTE: The DRBIII(R) must be at software Version 64.0 or later. 52. Turn the ignition key to "ON". 53. Press the "YES" button when the DRBIII(R) powers up. 54. Select "DRBIII(R) STANDALONE" and press "ENTER". 55. Select "1997-2007 DIAGNOSTICS" and press "ENTER". 56. Select "ALL" and press "ENTER". 57. Select "PASSIVE RESTRAINT" and press "ENTER". 58. Select "CLEAR DTCS". 59. Disconnect and remove the DRBIII(R) from the vehicle. 60. Reset clock. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement Technical Service Bulletin # J38 Date: 100420 Campaign - Front Air Bag Sensor Replacement April 2010 Dealer Service Instructions for: Customer Satisfaction Notification J38 Supplemental Front Airbag Sensors Models 2005-2006 (RS) Dodge Caravan, Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles built from January 19, 2005 through April 5, 2006 (MDH 011900 through 040500). IMPORTANT: Many of the vehicles within the above build period have already been repaired according to our warranty records, and therefore, have been excluded from this notification. Only the above vehicles originally sold or currently registered in certain states are involved. See the "Owner Notification and Service Scheduling" section for a list of states involved in this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The supplemental front airbag sensors on about 310,000 of the above vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Repair The right and left supplemental front airbag sensors must be replaced and the sensor wiring harness connectors must be inspected and replaced, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8073 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8074 Parts Information Special Tools The following special tools may be required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8075 Use the labor operation numbers and time allowances as shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicableable. Only vehicles originally sold or currently registered in the following states are involved in this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8076 To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure A. Supplemental Front Airbag Sensor Replacement 1. Lower the driver's window completely. 2. Open the hood. 3. Disconnect and isolate the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Raise the vehicle on a suitable hoist. 5. Disconnect the wiring harness connector to the right and left supplemental front airbag sensor. The sensors are located on the outside of the right and left frame rails at the radiator lower crossmember (Figure 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8077 6. Remove the right and left supplemental front airbag sensors and discard the sensors and retaining bolts. CAUTION: If the retaining bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose from the radiator lower crossmember. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensor retaining bolts, continue with Step 9. 7. Use the following procedure, if required, to replace a spun riv-nut: a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps. b. Remove the four screws (two each side) that secure the left and right wheelhouse splash shield to the front fascia. c. Remove the right and left side fascia-to-fender bolts. d. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. e. Partially lower the vehicle. f. Remove the right and left fascia bolts from the upper radiator crossmember (Figure 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8078 g. Pull the wheelhouse shield back from the front fascia and remove the right and left nuts holding the front fascia to the front lip of the fender (Figure 3). h. Carefully remove the front fascia and set it aside. CAUTION: Be careful not to scratch the painted surfaces of the front fascia and front fenders. i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard. j. Using a cut-off wheel, remove the head of the airbag sensor mounting bolt. k. Remove and discard the supplemental front airbag sensor bushing. l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool. NOTE: Be sure to completely remove the riv-nut from the lower radiator crossmember. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8079 n. Pre-assemble the new riv-nut by installing the installation nut and the riv-nut onto the installation bolt as shown in Figure 4. o. Insert the new riv-nut-bolt/nut assembly into the original riv-nut hole in the lower radiator crossmember. p. Using a 10mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5). q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut. r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely). 8. For vehicles that had the front fascia removed, use the following procedure to install the front fascia: a. Position the front fascia onto the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8080 b. Install the right and left upper fascia bolts finger tight (Figure 6). c. Install the right and left nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m). d. Install and tighten the two fascia-to-fender bolts. e. Install the four screws (two on each side) that secure the right and left wheelhouse shield to the front fascia. f. Using new push pins if necessary, install the air dam to the lower radiator crossmember. g. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps. h. Continue with Step 9. 9. Inspect the right and left supplemental front airbag sensor wiring connectors. > If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B. Airbag Sensor Harness Connector Replacement. > If there is no corrosion on either terminal of the harness connectors, continue with Section C. Supplemental Front Airbag Sensor Installation. B. Airbag Sensor Harness Connector(s) Replacement NOTE: Only those harness connector(s) that exhibit terminal corrosion, as described in Section A, require replacement. 1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector. 2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness. 3. Remove 1/2 inch (13 mm) of insulation from each wire. 4. Cut the new harness connector wires so that the final length is equal to the old harness. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8081 5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire. 6. Slide one piece of heat shrink tubing onto each of the harness connector wires. 7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just enough to hold the splice band in place. 8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows: > For the right (passenger side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the purple (w/blue tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the white (w/blue tracer) wire on the body wiring harness. > For the left (driver's side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the blue (w/purple tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the blue (w/white tracer) wire on the body wiring harness. CAUTION: Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band. 10. Crimp the splice band and wires together by squeezing the crimping tool handles. NOTE: The tool will release once the proper crimping force has been achieved. 11. Solder the connection together using only rosin core type solder. CAUTION: DO NOT use acid core solder. 12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing. CAUTION: Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure. 13. Continue with Section C. Supplemental Front Airbag Sensor Installation. C. Supplemental Front Airbag Sensor Installation 1. Clean the supplemental front airbag sensor mounting surface for both sensors. 2. Install the new supplemental front airbag sensors using the fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091. NOTE: Use the bolts with a blue thread locker patch on the threads. Discard the pointed self tapping screws and flat washers. They will not be used in this repair procedure. 3. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. 4. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8082 5. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector (Figure 7). NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor wiring harness connector. 6. Connect the wiring harness connectors to the right and left supplemental front airbag sensors. 7. Lower the vehicle from the hoist. 8. For vehicles that had the Fascia removed, tighten the upper fascia bolts to 50 in. lbs. (5 N.m). 9. Connect the negative battery cable to the battery. 10. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "RUN" position. Wait 10 seconds: > If the airbag warning light is not illuminated, the repair has been completed. No further action is required, return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 11 to clear the Diagnostic Trouble Codes (DTC's). 11. Use the following procedure to clear DTC's: a. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. b. Turn the ignition key to the "RUN" position. c. Press the "YES" button after the DRBIII powers up. d. Select "DRBIII STANDALONE" and press "ENTER". e. Select "1998-2007 DIAGNOSTICS" and press "ENTER". f. Select "ALL" and press "ENTER". g. Select "PASSIVE RESTRAINT" and press "ENTER". h. Select "AIRBAG" and press "ENTER". i. Select "READ DTC's" and press "ENTER". j. Select "STORED" and press "ENTER". k. Press the "PAGE BACK" button and follow the screen prompts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8083 l. Disconnect and remove the DRBIII from the vehicle and return the vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set Technical Service Bulletin # 08-020-07 Date: 070713 Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set NUMBER: 08-020-07 GROUP: Electrical DATE: July 13, 2007 SUBJECT: Supplemental Front Air Bag Sensor Replacement (Lifetime Warranty) OVERVIEW: This bulletin involves verifying that a right and/or left front impact supplemental airbag sensor(s) Diagnostic Trouble Code (DTC) exists in the Occupant Restraint Control Module (ORG). If DTC's exist, the right and left supplemental front airbag sensors must be replaced and the sensor harness connectors must be inspected for corrosion and replaced if necessary. NOTE: Technicians performing this procedure for the first time should fully familiarize themselves with the steps and procedures listed in this Service Bulletin before proceeding. MODELS: 2005 (RG) Chrysler Voyager 2005 (RS) Town & Country/Caravan/Voyager NOTE: This bulletin applies to vehicles built at the Windsor Assembly Plant ("R" in the 11th VIN position) through February 3, 2005 (MDH 020323), the St. Louis Assembly plant ("B" in the 11th VIN position) through January 19, 2005 (MDH 011923) or the Styler Assembly plant ("Y" in the 11th VIN position) through January 04, 2005 (MDH 010423). DISCUSSION: The supplemental front airbag sensors may crack under certain conditions and allow water to enter into the sensor(s). These sensors were added to enhance the performance of the vehicles airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. DIAGNOSIS: If the vehicle operator experiences air bag warning lamp illumination with any of the following DTC's; NO RIGHT FRONT IMPACT SENSOR COMMUNICATION / RIGHT FRONT IMPACT SENSOR INTERNAL 1/ NO LEFT FRONT IMPACT SENSOR COMMUNICATION or LEFT FRONT IMPACT SENSOR INTERNAL 1, perform the Repair Procedure. If the air bag warning lamp is on due to other DTC's, this bulletin does not apply. Refer to diagnostic procedures available in DealerCONNECT >>> TechCONNECT under: Diagnostics > 7.2 AIRBAG for further information. NOTE: Vehicles that are included in Customer Satisfaction Notification G09 are not included in this Service Bulletin and must be repaired under the procedures and labor operation numbers listed within G09. Vehicles not included in G09 must use this Service Bulletin for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8088 PARTS REQUIRED: NOTE: Connectors, Self-Tapping Screws and Riv-nuts will be used on an "as needed" basis. SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. NOTE: Vehicles included in this Service Bulletin have a lifetime warranty on supplemental front airbag sensors, mounting hardware and sensor electrical connectors as described in this Service Bulletin. See Warranty Bulletin D-07-19 for details associated with the lifetime warranty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8089 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Lower the driver's side window. 2. Disconnect the Negative Battery Cable. 3. Refer to the detailed removal procedures available in DealerCONNECT >>> TechCONNECT under: Service Information Tab >>> Group 8, Electrical >>> Restraints >>> Impact Sensor >>> Removal. 4. When removing the attaching bolts for the sensor, does any of the bolts spin freely and not come out? (See NOTES below). a. Yes >>> Proceed to Step # 5 b. No >>> Proceed to Step # 22 NOTE: There are 2 types of bolts used to fasten the sensors to the radiator crossmember; a M7 self tapping bolt or a M6 bolt used with a riv-nut. If the bolt spins and cannot be removed, the riv-nut has broken loose. If the riv-nut spins and the bolt cannot be removed, proceed to next step to replace riv-nut(s). If no issue with the riv-nut is found, proceed to Step # 22. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8090 NOTE: The riv-nut procedure is applicable for vehicles built at the Windsor Assembly plant after May 24, 2004 or the St. Louis Assembly plant after June 28, 2004 or the Styler Assembly plant after June 28, 2004. Very few vehicles will require riv-nut replacement. 5. If the vehicle equipped with fog lamps, disconnect electrical harness connectors from both fog lamps. 6. Remove the 2 screws that secure the left and right wheelhouse splash shield to the front fascia. 7. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. 8. Remove the right and left fascia upper bolts from the upper radiator crossmember. (Fig 2) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8091 9. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Fig. 3) 10. Remove 2 vertical screws holding the front fascia to the front fender. 11. Carefully remove the front fascia and set aside. CAUTION: Care should be used not to damage painted surfaces. 12. Break the front air bag sensor using a suitable tool. Remove broken sensor pieces. 13. Using a powered cut-off wheel, remove the head of the sensor mounting bolt. 14. Remove sensor bushing from bolt. 15. Using a powered cut-off wheel, cut the bolt and lip of the riv-nut flush with sheet metal. 16. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. 17. Remove the old riv-nut through the access hole in the crossmember using a magnetic tool. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8092 18. Preassemble the new riv-nut, p/n CBX2G093 by installing the M6 nut, and the riv-nut onto the bolt, as shown in (Fig. 4). 19. Insert the riv-nut and bolt assembly into the original mounting hole. 20. Using a 10 mm crows foot, tighten the installation nut to 9 Nm, (80 in. lb) while holding the installation bolt stationary (Fig. 5). 21. Repeat Step # 12 through Step # 20 for remaining riv-nut(s) that have broken loose and spin freely. 22. Clean the mounting surface for both sensors. 23. Install the new sensors using the appropriate fasteners; Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8093 a. For sensors fastened with self-tapping bolts. Proceed to >>> # 24. b. For sensors fastened with M6 bolts and riv-nuts. Proceed to >>> Step # 26. 24. For self-tapping fastener installation; preassemble both air bag sensors with self-tapping bolts and washers (Fig. 6). 25. Position the sensors on the vehicle and tighten each self-tapping bolt into the mounting hole about 5 turns to cut new threads for the larger M7 bolt. Tighten to 7 Nm, (60 in. lb). Proceed to Step # 27. 26. For M6 bolt and riv-nut fastener installation; hand start both bolts in sensors. Tighten to 7 Nm, (60 in. lb). 27. Inspect the right and left air bag sensor wiring connectors. Is there is any sign of corrosion, (white, green or black), on either terminal of the harness connectors? a. Yes >>> Proceed to Step # 28. b. No >>> Proceed to Step # 39. NOTE: Only replace harness connectors that exhibit terminal corrosion. 28. Cut wire harness 3 in. (75 mm) back from connector. 29. Remove 1 in. (25 mm) of black tape from wire harness going to the vehicle. 30. Strip .5 in. (13 mm) of insulation from each wire. 31. Cut the new sensor connector wire harness p/n CBX2G092 the same length as the removed connector wire harness. 32. Strip .5 in. (13 mm) of insulation from each wire. 33. Slide one piece of heat shrink tubing on each of the wires. 34. Load and center the splice band into cavity "B" of crimp tool # 10042. Close the tool just enough to hold the splice band in place NOTE: First time use of crimp tool #10042 will require the crimp dies to be installed on the crimper frame. Orient the upper die with the arrow pointed up and the lower die with the arrow pointed forward. The numbers on upper die and letters on lower die will be on the same side. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8094 35. Match the new harness connector wires to the existing vehicle harness as follows: a. For the right (passenger side) sensor, match the new harness connector wire colors to the same color wire on the existing vehicle wire harness. b. For the left (driver side) sensor, match the new harness connector wire colors to the same tracer stripe color wire on the existing vehicle wire harness. CAUTION: Ensure wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 36. Insert the matched bare wires through the crimp connector from opposite ends. Crimp the connections using #10042 wire splice crimp tool. 37. Solder the crimped connection using only rosin-core solder. 38. Center heat shrink tubing over the connection and heat with a heat gun until tubing is tight and sealant is witnessed at the ends (Fig 7). CAUTION: Use only the sealant lined heat shrink tube supplied in wiring kit above. Use of electrical tape or non-sealant lined heat shrink tube may cause circuit failure. 39. Apply a small amount of dielectric grease, p/n J81 26688 to the airbag sensor connector end. Using a finger, force the grease into the terminal connections of the airbag sensor connector. 40. Connect the harness connectors to both front airbag sensors. 41. Has the fascia been removed? a. Yes >>> Proceed to Step # 42. b. No >>> Proceed to Step # 49. 42. Position the front fascia onto the vehicle. 43. Install the right and left upper fascia bolts, tighten to 5 Nm (50 in lb). 44. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender and tighten to 7 Nm (60 in lb). 45. Install the two vertical screws that secure the front fascia to the front fenders. 46. Install the two screws that secure the right and left wheelhouse shield to the front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8095 47. Using new push pins, if necessary, securing the air dam to the lower radiator crossmember. 48. Connect the electrical harness connectors to the right and left fog lamps, if equipped. 49. Connect the negative battery cable to the battery. 50. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel, and turn the ignition key to the "ON position. Wait 10 seconds: a. If the airbag warning light is not illuminated, the repair is complete. Proceed to to clear stored DTC's. b. If the airbag warning light is illuminated due to supplemental front airbag sensor faults, switch the ignition key "OFF and Proceed to and clear any DTC's. If the DTC's return and ARE related to the Front Impact Sensor(s), Verify proper wiring connections as described in above. If wiring connections are correct, or if DTC's are related to other components of the supplemental airbag system, refer to the diagnostic information available in DealerCONNECT >>> TechCONNECT under: Diagnostics > 7.2 AIRBAG for further information. 51. Turn the ignition "OFF" and connect the DRBIII(R). NOTE: The DRBIII(R) must be at software Version 64.0 or later. 52. Turn the ignition key to "ON". 53. Press the "YES" button when the DRBIII(R) powers up. 54. Select "DRBIII(R) STANDALONE" and press "ENTER". 55. Select "1997-2007 DIAGNOSTICS" and press "ENTER". 56. Select "ALL" and press "ENTER". 57. Select "PASSIVE RESTRAINT" and press "ENTER". 58. Select "CLEAR DTCS". 59. Disconnect and remove the DRBIII(R) from the vehicle. 60. Reset clock. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement Technical Service Bulletin # G09 Date: 070601 Recall - Front Air Bag Impact Sensor Replacement June 2007 Dealer Service Instructions for: Customer Satisfaction Notification G09 Supplemental Front Airbag Sensors Models 2005 (RS) Dodge Caravan, Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles built at the Windsor Assembly plant ("R" in the 11th VIN position) through February 3, 2005 (MDH 020323) and the St. Louis Assembly plant ("B" in the 11th VIN position) through January 19, 2005 (MDH 011923). IMPORTANT: Many of the vehicles within the above build period have already been repaired according to our warranty records, and therefore, have been excluded from this notification. Only the above vehicles originally sold or currently registered in certain states are involved. See the "Owner Notification and Service Scheduling" section for a list of states involved in this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair service on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The supplemental front airbag sensors on about 263,000 of the above vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Repair The right and left supplemental front airbag sensors must be replaced and the sensor harness connectors must be inspected and replaced, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8100 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8101 Parts Information Special Tools The special tools may be required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record repair service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8102 Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Attached to each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Only vehicles originally sold or currently registered in the following states are involved in this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Supplemental Front Airbag Sensor Replacement 1. Lower the driver¡C■s window completely. 2. Open the hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8103 3. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Raise the vehicle on a suitable hoist. 5. Disconnect the harness connector to the right and left supplemental front airbag sensor (Figure 1). 6. Remove the right and left supplemental front airbag sensors and discard the bolts and sensors. NOTE: There are two types of bolts used to fasten the sensors to the radiator crossmember; an M7 self tapping bolt or an M6 bolt used with a riv-nut. If the bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensors, continue with Step 8. 7. Replaced a spun riv-nut as follows: NOTE: The following procedure is applicable for vehicle built at the Windsor Assembly Plant after May 24, 2004 or the St. Louis Assembly Plant after June 28, 2004. Very few vehicles are expected to require riv-nut replacement. a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps. b. Remove the two screws that secure the left and right wheelhouse splash shield to the front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8104 c Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. d. Partially lower the vehicle. e. Remove the right and left fascia upper bolts from the upper radiator crossmember (Figure 2). f. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Figure 3) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8105 g. Remove the two vertical screws holding the front fascia to the front fender. h. Carefully remove the front fascia and set it aside. CAUTION: Be careful not to scratch the painted surfaces of the front fascia and the front fenders. i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard. j. Using a cut-off wheel, cut off the head of the airbag sensor mounting bolt. k. Remove and discard the supplemental front airbag sensor bushing. l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool. NOTE: Be sure to completely remove the riv-nut from the lower radiator crossmember. n. Pre-assemble the new riv-nut by installing the M6 nut and the riv-nut onto the M6 bolt as shown in Figure 4. o. Insert the riv-nut-bolt/nut assembly into the body sheet metal hole. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8106 p. Using a 10 mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5). q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut. r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely). s. Clean the supplemental front airbag sensor mounting surface for both sensors. t. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091: > For sensors fastened with self tapping bolts: a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6. b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts. c. Tightening the self tapping bolts to 60 in.lbs. (7 N.m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8107 > For sensors fastened with M6 bolts and riv-nuts: a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). u. Inspect the right and left supplemental front airbag sensor wiring connectors. If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B Harness Connector Replacement. v. Position the front fascia onto the vehicle. w. Install the right and left upper bolts fascia bolts and tighten to 50 in. lbs. (5 N.m). x. Install the right and left horizontal nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m). y. Install and tighten the two vertical screws that secure the front fascia to the front fenders. z. Install the two screws that secure the right and left wheelhouse shield to the front fascia. aa. Using new push pins if necessary, install the air dam to the lower radiator crossmember. ab. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps. ac. Continue with Step 10. 8. Clean the supplemental front airbag sensor mounting surface for both sensors. 9. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091: > For sensors fastened with self tapping bolts: a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6. b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts. c. Tightening the self tapping bolts to 60 in. lbs. (7 N.m). > For sensors fastened with M6 bolts and riv-nuts: a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). 10. Inspect the right and left supplemental front airbag sensor wiring connectors. If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B - Harness Connector Replacement. 11. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector. NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector. 12. Connect harness connectors to the right and left supplemental front airbag sensors. 13. Lower the vehicle. 14. Connect the negative battery cable to the battery. 15. Stand next to the vehicle with the driver¡C■s door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "ON" position. Wait 10 seconds: > If the airbag warning light is not illuminated the repair has been completed. Return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8108 continue with Step 16 to clear the sensor DTC. 16. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. 17. Turn the ignition key to the "ON" position. 18. Press the "YES" button when the DRBIII powers up. 19. Select "DRBIII STANDALONE" and press "ENTER". 20. Select "1997-2007 DIAGNOSTICS" and press "ENTER". 21. Select "ALL" and press "ENTER" 22. Select "PASSIVE RESTRAINT" and press "ENTER". 23. Select "CLEAR DTCS". 24. Disconnect and remove the DRBIII from the vehicle. B. Airbag Sensor Harness Connector Replacement NOTE: Only those harness connectors that exhibit terminal corrosion, as described in Section A, require replacement. 1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector. 2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness. 3. Remove 1/2 inch (13 mm) of insulation from each wire. 4. Cut the new harness connector wires so that the final length is equal to the old harness. 5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire. 6. Slide one piece of heat shrink tubing onto each of the harness connector wires. 7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just the tool just CAUTION: The crimp jaw must be installed in the crimp tool frame as shown in Figure 7. The crimp jaw wire gauge numbers must be on the same side. When installing the crimp jaw into the tool frame, orient the upper die with the arrow pointed "up" and the lower die with the arrow pointed forward. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8109 8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows: > For the right (passenger side) supplemental front airbag sensor, match the new harness connector wire colors to the same color wire on the existing body wire harness. > For the left (driver's side) supplemental front airbag sensor, match the new harness connector wire colors to same tracer (stripe) color wire on the existing body wire harness. CAUTION: Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. warning lamp. 9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band (Figure 8). 10. Crimp the splice band and wires together by squeezing the crimping tool handles. The tool will release once the proper crimping force has been achieved (Figure 8). 11. Solder the connection together using only rosin-core type solder (Figure. 9). CAUTION: DO NOT use acid core solder. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8110 12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Figure 10). CAUTION: Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure. 13. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector. NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector. 14. Connect harness connectors to the right and left supplemental front airbag sensors. 15. For vehicles with the front fascia removed: a. Position the front fascia onto the vehicle. b. Install the right and left upper fascia bolts and tighten to 50 in. lbs. (5 N.m). c. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender. Tighten the nuts to 60 in. lbs. (7 N.m). d. Install and tighten the two vertical screws that secure the front fascia to the front fenders. e. Install the two screws that secure the right and left wheelhouse shield to the front fascia. f. Using new push pins if necessary, securing the air dam to the lower radiator crossmember. g. For vehicles with fog lamps, connect the electrical harness connectors to the right and left fog lamps. 16. Lower the vehicle. 17. Connect the negative battery cable to the battery. 18. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel, and turn the ignition key to the "ON" position. Wait 10 seconds: > If the airbag warning light is not illuminated, the repair has been completed. Return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 19 to clear the sensor DTC. 19. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. 20. Turn the ignition key to the "ON" position. 21. Press the "YES" button when the DRBIII powers up. 22. Select "DRBIII STANDALONE" and press "ENTER". 23. Select "1997-2007 DIAGNOSTICS" and press "ENTER". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8111 24. Select "ALL" and press "ENTER". 25. Select "PASSIVE RESTRAINT" and press "ENTER". 26. Select "CLEAR DTCS". 27. Disconnect and remove the DRBIII from the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Impact Sensor: > NHTSA07V192000 > May > 07 > Recall 07V191000: Air Bag Impact Sensor Replacement Impact Sensor: All Technical Service Bulletins Recall 07V191000: Air Bag Impact Sensor Replacement MAKE/MODELS: MODEL/BUILD YEARS: Chrysler/Town & Country 2005 Dodge/Caravan 2005 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V192000 MFR'S REPORT DATE: May 01, 2007 COMPONENT: Air Bags: Frontal: Sensor/Control Module POTENTIAL NUMBER OF UNITS AFFECTED: 270958 SUMMARY: Certain minivans are being recalled that were originally sold in or currently registered in the 27 states plus The District of Columbia that use greater amounts of salt for Winter road deicing. The Up-Front (UF) air bag sensors that contain brass bushings installed in these vehicles may corrode and crack allowing water to enter the sensor. These sensors provide enhanced air bag performance in certain types of frontal crashes. CONSEQUENCE: In one of these crashes, with one or both of the vehicle the vehicle's UF sensors inoperative, the occupants will not benefit from the enhanced air bag protection that these sensors would provide. REMEDY: For vehicles registered in the recall states, dealers will replace the original UF air bag sensors with ones with greater corrosion resistance. Vehicles registered in other states will obtain a lifetime free replacement of any UF sensor that fails. The campaign is expected to begin during July 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler's campaign Nos. G09/X16. DaimlerChrysler has not decided that this is a defect related to motor vehicle safety. However, it has informed NHTSA that it will provide the modifications described above free of charge. Customers also may contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline aT 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set Technical Service Bulletin # 08-020-07 Date: 070713 Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set NUMBER: 08-020-07 GROUP: Electrical DATE: July 13, 2007 SUBJECT: Supplemental Front Air Bag Sensor Replacement (Lifetime Warranty) OVERVIEW: This bulletin involves verifying that a right and/or left front impact supplemental airbag sensor(s) Diagnostic Trouble Code (DTC) exists in the Occupant Restraint Control Module (ORG). If DTC's exist, the right and left supplemental front airbag sensors must be replaced and the sensor harness connectors must be inspected for corrosion and replaced if necessary. NOTE: Technicians performing this procedure for the first time should fully familiarize themselves with the steps and procedures listed in this Service Bulletin before proceeding. MODELS: 2005 (RG) Chrysler Voyager 2005 (RS) Town & Country/Caravan/Voyager NOTE: This bulletin applies to vehicles built at the Windsor Assembly Plant ("R" in the 11th VIN position) through February 3, 2005 (MDH 020323), the St. Louis Assembly plant ("B" in the 11th VIN position) through January 19, 2005 (MDH 011923) or the Styler Assembly plant ("Y" in the 11th VIN position) through January 04, 2005 (MDH 010423). DISCUSSION: The supplemental front airbag sensors may crack under certain conditions and allow water to enter into the sensor(s). These sensors were added to enhance the performance of the vehicles airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. DIAGNOSIS: If the vehicle operator experiences air bag warning lamp illumination with any of the following DTC's; NO RIGHT FRONT IMPACT SENSOR COMMUNICATION / RIGHT FRONT IMPACT SENSOR INTERNAL 1/ NO LEFT FRONT IMPACT SENSOR COMMUNICATION or LEFT FRONT IMPACT SENSOR INTERNAL 1, perform the Repair Procedure. If the air bag warning lamp is on due to other DTC's, this bulletin does not apply. Refer to diagnostic procedures available in DealerCONNECT >>> TechCONNECT under: Diagnostics > 7.2 AIRBAG for further information. NOTE: Vehicles that are included in Customer Satisfaction Notification G09 are not included in this Service Bulletin and must be repaired under the procedures and labor operation numbers listed within G09. Vehicles not included in G09 must use this Service Bulletin for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8121 PARTS REQUIRED: NOTE: Connectors, Self-Tapping Screws and Riv-nuts will be used on an "as needed" basis. SPECIAL TOOLS / EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. NOTE: Vehicles included in this Service Bulletin have a lifetime warranty on supplemental front airbag sensors, mounting hardware and sensor electrical connectors as described in this Service Bulletin. See Warranty Bulletin D-07-19 for details associated with the lifetime warranty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8122 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure 1. Lower the driver's side window. 2. Disconnect the Negative Battery Cable. 3. Refer to the detailed removal procedures available in DealerCONNECT >>> TechCONNECT under: Service Information Tab >>> Group 8, Electrical >>> Restraints >>> Impact Sensor >>> Removal. 4. When removing the attaching bolts for the sensor, does any of the bolts spin freely and not come out? (See NOTES below). a. Yes >>> Proceed to Step # 5 b. No >>> Proceed to Step # 22 NOTE: There are 2 types of bolts used to fasten the sensors to the radiator crossmember; a M7 self tapping bolt or a M6 bolt used with a riv-nut. If the bolt spins and cannot be removed, the riv-nut has broken loose. If the riv-nut spins and the bolt cannot be removed, proceed to next step to replace riv-nut(s). If no issue with the riv-nut is found, proceed to Step # 22. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8123 NOTE: The riv-nut procedure is applicable for vehicles built at the Windsor Assembly plant after May 24, 2004 or the St. Louis Assembly plant after June 28, 2004 or the Styler Assembly plant after June 28, 2004. Very few vehicles will require riv-nut replacement. 5. If the vehicle equipped with fog lamps, disconnect electrical harness connectors from both fog lamps. 6. Remove the 2 screws that secure the left and right wheelhouse splash shield to the front fascia. 7. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. 8. Remove the right and left fascia upper bolts from the upper radiator crossmember. (Fig 2) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8124 9. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Fig. 3) 10. Remove 2 vertical screws holding the front fascia to the front fender. 11. Carefully remove the front fascia and set aside. CAUTION: Care should be used not to damage painted surfaces. 12. Break the front air bag sensor using a suitable tool. Remove broken sensor pieces. 13. Using a powered cut-off wheel, remove the head of the sensor mounting bolt. 14. Remove sensor bushing from bolt. 15. Using a powered cut-off wheel, cut the bolt and lip of the riv-nut flush with sheet metal. 16. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. 17. Remove the old riv-nut through the access hole in the crossmember using a magnetic tool. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8125 18. Preassemble the new riv-nut, p/n CBX2G093 by installing the M6 nut, and the riv-nut onto the bolt, as shown in (Fig. 4). 19. Insert the riv-nut and bolt assembly into the original mounting hole. 20. Using a 10 mm crows foot, tighten the installation nut to 9 Nm, (80 in. lb) while holding the installation bolt stationary (Fig. 5). 21. Repeat Step # 12 through Step # 20 for remaining riv-nut(s) that have broken loose and spin freely. 22. Clean the mounting surface for both sensors. 23. Install the new sensors using the appropriate fasteners; Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8126 a. For sensors fastened with self-tapping bolts. Proceed to >>> # 24. b. For sensors fastened with M6 bolts and riv-nuts. Proceed to >>> Step # 26. 24. For self-tapping fastener installation; preassemble both air bag sensors with self-tapping bolts and washers (Fig. 6). 25. Position the sensors on the vehicle and tighten each self-tapping bolt into the mounting hole about 5 turns to cut new threads for the larger M7 bolt. Tighten to 7 Nm, (60 in. lb). Proceed to Step # 27. 26. For M6 bolt and riv-nut fastener installation; hand start both bolts in sensors. Tighten to 7 Nm, (60 in. lb). 27. Inspect the right and left air bag sensor wiring connectors. Is there is any sign of corrosion, (white, green or black), on either terminal of the harness connectors? a. Yes >>> Proceed to Step # 28. b. No >>> Proceed to Step # 39. NOTE: Only replace harness connectors that exhibit terminal corrosion. 28. Cut wire harness 3 in. (75 mm) back from connector. 29. Remove 1 in. (25 mm) of black tape from wire harness going to the vehicle. 30. Strip .5 in. (13 mm) of insulation from each wire. 31. Cut the new sensor connector wire harness p/n CBX2G092 the same length as the removed connector wire harness. 32. Strip .5 in. (13 mm) of insulation from each wire. 33. Slide one piece of heat shrink tubing on each of the wires. 34. Load and center the splice band into cavity "B" of crimp tool # 10042. Close the tool just enough to hold the splice band in place NOTE: First time use of crimp tool #10042 will require the crimp dies to be installed on the crimper frame. Orient the upper die with the arrow pointed up and the lower die with the arrow pointed forward. The numbers on upper die and letters on lower die will be on the same side. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8127 35. Match the new harness connector wires to the existing vehicle harness as follows: a. For the right (passenger side) sensor, match the new harness connector wire colors to the same color wire on the existing vehicle wire harness. b. For the left (driver side) sensor, match the new harness connector wire colors to the same tracer stripe color wire on the existing vehicle wire harness. CAUTION: Ensure wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 36. Insert the matched bare wires through the crimp connector from opposite ends. Crimp the connections using #10042 wire splice crimp tool. 37. Solder the crimped connection using only rosin-core solder. 38. Center heat shrink tubing over the connection and heat with a heat gun until tubing is tight and sealant is witnessed at the ends (Fig 7). CAUTION: Use only the sealant lined heat shrink tube supplied in wiring kit above. Use of electrical tape or non-sealant lined heat shrink tube may cause circuit failure. 39. Apply a small amount of dielectric grease, p/n J81 26688 to the airbag sensor connector end. Using a finger, force the grease into the terminal connections of the airbag sensor connector. 40. Connect the harness connectors to both front airbag sensors. 41. Has the fascia been removed? a. Yes >>> Proceed to Step # 42. b. No >>> Proceed to Step # 49. 42. Position the front fascia onto the vehicle. 43. Install the right and left upper fascia bolts, tighten to 5 Nm (50 in lb). 44. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender and tighten to 7 Nm (60 in lb). 45. Install the two vertical screws that secure the front fascia to the front fenders. 46. Install the two screws that secure the right and left wheelhouse shield to the front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > 08-020-07 > Jul > 07 > Restraints - Air Bag Lamp ON/Impact Sensor DTC's Set > Page 8128 47. Using new push pins, if necessary, securing the air dam to the lower radiator crossmember. 48. Connect the electrical harness connectors to the right and left fog lamps, if equipped. 49. Connect the negative battery cable to the battery. 50. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel, and turn the ignition key to the "ON position. Wait 10 seconds: a. If the airbag warning light is not illuminated, the repair is complete. Proceed to to clear stored DTC's. b. If the airbag warning light is illuminated due to supplemental front airbag sensor faults, switch the ignition key "OFF and Proceed to and clear any DTC's. If the DTC's return and ARE related to the Front Impact Sensor(s), Verify proper wiring connections as described in above. If wiring connections are correct, or if DTC's are related to other components of the supplemental airbag system, refer to the diagnostic information available in DealerCONNECT >>> TechCONNECT under: Diagnostics > 7.2 AIRBAG for further information. 51. Turn the ignition "OFF" and connect the DRBIII(R). NOTE: The DRBIII(R) must be at software Version 64.0 or later. 52. Turn the ignition key to "ON". 53. Press the "YES" button when the DRBIII(R) powers up. 54. Select "DRBIII(R) STANDALONE" and press "ENTER". 55. Select "1997-2007 DIAGNOSTICS" and press "ENTER". 56. Select "ALL" and press "ENTER". 57. Select "PASSIVE RESTRAINT" and press "ENTER". 58. Select "CLEAR DTCS". 59. Disconnect and remove the DRBIII(R) from the vehicle. 60. Reset clock. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement Technical Service Bulletin # J38 Date: 100420 Campaign - Front Air Bag Sensor Replacement April 2010 Dealer Service Instructions for: Customer Satisfaction Notification J38 Supplemental Front Airbag Sensors Models 2005-2006 (RS) Dodge Caravan, Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles built from January 19, 2005 through April 5, 2006 (MDH 011900 through 040500). IMPORTANT: Many of the vehicles within the above build period have already been repaired according to our warranty records, and therefore, have been excluded from this notification. Only the above vehicles originally sold or currently registered in certain states are involved. See the "Owner Notification and Service Scheduling" section for a list of states involved in this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The supplemental front airbag sensors on about 310,000 of the above vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Repair The right and left supplemental front airbag sensors must be replaced and the sensor wiring harness connectors must be inspected and replaced, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8134 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8135 Parts Information Special Tools The following special tools may be required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by Chrysler to record Customer Satisfaction Notification service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8136 Use the labor operation numbers and time allowances as shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dealer Notification To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to Chrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicableable. Only vehicles originally sold or currently registered in the following states are involved in this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8137 To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers should perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this notification only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations Chrysler Group LLC Service Procedure A. Supplemental Front Airbag Sensor Replacement 1. Lower the driver's window completely. 2. Open the hood. 3. Disconnect and isolate the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Raise the vehicle on a suitable hoist. 5. Disconnect the wiring harness connector to the right and left supplemental front airbag sensor. The sensors are located on the outside of the right and left frame rails at the radiator lower crossmember (Figure 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8138 6. Remove the right and left supplemental front airbag sensors and discard the sensors and retaining bolts. CAUTION: If the retaining bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose from the radiator lower crossmember. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensor retaining bolts, continue with Step 9. 7. Use the following procedure, if required, to replace a spun riv-nut: a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps. b. Remove the four screws (two each side) that secure the left and right wheelhouse splash shield to the front fascia. c. Remove the right and left side fascia-to-fender bolts. d. Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. e. Partially lower the vehicle. f. Remove the right and left fascia bolts from the upper radiator crossmember (Figure 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8139 g. Pull the wheelhouse shield back from the front fascia and remove the right and left nuts holding the front fascia to the front lip of the fender (Figure 3). h. Carefully remove the front fascia and set it aside. CAUTION: Be careful not to scratch the painted surfaces of the front fascia and front fenders. i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard. j. Using a cut-off wheel, remove the head of the airbag sensor mounting bolt. k. Remove and discard the supplemental front airbag sensor bushing. l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool. NOTE: Be sure to completely remove the riv-nut from the lower radiator crossmember. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8140 n. Pre-assemble the new riv-nut by installing the installation nut and the riv-nut onto the installation bolt as shown in Figure 4. o. Insert the new riv-nut-bolt/nut assembly into the original riv-nut hole in the lower radiator crossmember. p. Using a 10mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5). q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut. r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely). 8. For vehicles that had the front fascia removed, use the following procedure to install the front fascia: a. Position the front fascia onto the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8141 b. Install the right and left upper fascia bolts finger tight (Figure 6). c. Install the right and left nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m). d. Install and tighten the two fascia-to-fender bolts. e. Install the four screws (two on each side) that secure the right and left wheelhouse shield to the front fascia. f. Using new push pins if necessary, install the air dam to the lower radiator crossmember. g. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps. h. Continue with Step 9. 9. Inspect the right and left supplemental front airbag sensor wiring connectors. > If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B. Airbag Sensor Harness Connector Replacement. > If there is no corrosion on either terminal of the harness connectors, continue with Section C. Supplemental Front Airbag Sensor Installation. B. Airbag Sensor Harness Connector(s) Replacement NOTE: Only those harness connector(s) that exhibit terminal corrosion, as described in Section A, require replacement. 1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector. 2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness. 3. Remove 1/2 inch (13 mm) of insulation from each wire. 4. Cut the new harness connector wires so that the final length is equal to the old harness. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8142 5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire. 6. Slide one piece of heat shrink tubing onto each of the harness connector wires. 7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just enough to hold the splice band in place. 8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows: > For the right (passenger side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the purple (w/blue tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the white (w/blue tracer) wire on the body wiring harness. > For the left (driver's side) supplemental front airbag sensor, connect the purple wire on the new connector wiring harness to the blue (w/purple tracer) wire on the body wiring harness. Connect the white wire on the new connector wiring harness to the blue (w/white tracer) wire on the body wiring harness. CAUTION: Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. 9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band. 10. Crimp the splice band and wires together by squeezing the crimping tool handles. NOTE: The tool will release once the proper crimping force has been achieved. 11. Solder the connection together using only rosin core type solder. CAUTION: DO NOT use acid core solder. 12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing. CAUTION: Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure. 13. Continue with Section C. Supplemental Front Airbag Sensor Installation. C. Supplemental Front Airbag Sensor Installation 1. Clean the supplemental front airbag sensor mounting surface for both sensors. 2. Install the new supplemental front airbag sensors using the fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091. NOTE: Use the bolts with a blue thread locker patch on the threads. Discard the pointed self tapping screws and flat washers. They will not be used in this repair procedure. 3. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. 4. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8143 5. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector (Figure 7). NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor wiring harness connector. 6. Connect the wiring harness connectors to the right and left supplemental front airbag sensors. 7. Lower the vehicle from the hoist. 8. For vehicles that had the Fascia removed, tighten the upper fascia bolts to 50 in. lbs. (5 N.m). 9. Connect the negative battery cable to the battery. 10. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "RUN" position. Wait 10 seconds: > If the airbag warning light is not illuminated, the repair has been completed. No further action is required, return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 11 to clear the Diagnostic Trouble Codes (DTC's). 11. Use the following procedure to clear DTC's: a. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. b. Turn the ignition key to the "RUN" position. c. Press the "YES" button after the DRBIII powers up. d. Select "DRBIII STANDALONE" and press "ENTER". e. Select "1998-2007 DIAGNOSTICS" and press "ENTER". f. Select "ALL" and press "ENTER". g. Select "PASSIVE RESTRAINT" and press "ENTER". h. Select "AIRBAG" and press "ENTER". i. Select "READ DTC's" and press "ENTER". j. Select "STORED" and press "ENTER". k. Press the "PAGE BACK" button and follow the screen prompts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > J38 > Apr > 10 > Campaign - Front Air Bag Sensor Replacement > Page 8144 l. Disconnect and remove the DRBIII from the vehicle and return the vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement Technical Service Bulletin # G09 Date: 070601 Recall - Front Air Bag Impact Sensor Replacement June 2007 Dealer Service Instructions for: Customer Satisfaction Notification G09 Supplemental Front Airbag Sensors Models 2005 (RS) Dodge Caravan, Grand Caravan and Chrysler Town & Country NOTE: This notification applies only to the above vehicles built at the Windsor Assembly plant ("R" in the 11th VIN position) through February 3, 2005 (MDH 020323) and the St. Louis Assembly plant ("B" in the 11th VIN position) through January 19, 2005 (MDH 011923). IMPORTANT: Many of the vehicles within the above build period have already been repaired according to our warranty records, and therefore, have been excluded from this notification. Only the above vehicles originally sold or currently registered in certain states are involved. See the "Owner Notification and Service Scheduling" section for a list of states involved in this notification. IMPORTANT: Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete this repair service on these vehicles before retail delivery. Dealers should also perform this repair on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The supplemental front airbag sensors on about 263,000 of the above vehicles may crack under certain conditions and allow water to enter into the sensor. These sensors were added to enhance the performance of the vehicle's airbag system; however, a cracked sensor may not operate properly in a frontal crash. A cracked sensor can also illuminate the airbag warning light. Repair The right and left supplemental front airbag sensors must be replaced and the sensor harness connectors must be inspected and replaced, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8149 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8150 Parts Information Special Tools The special tools may be required to perform this repair: Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record repair service completions and provide dealer payments. Use the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete claim processing instructions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8151 Dealer Notification All dealers will receive three copies of this dealer recall notification letter by mail. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Attached to each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Only vehicles originally sold or currently registered in the following states are involved in this notification. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Supplemental Front Airbag Sensor Replacement 1. Lower the driver¡C■s window completely. 2. Open the hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8152 3. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 4. Raise the vehicle on a suitable hoist. 5. Disconnect the harness connector to the right and left supplemental front airbag sensor (Figure 1). 6. Remove the right and left supplemental front airbag sensors and discard the bolts and sensors. NOTE: There are two types of bolts used to fasten the sensors to the radiator crossmember; an M7 self tapping bolt or an M6 bolt used with a riv-nut. If the bolt spins freely and cannot be removed, the sensor's riv-nut has broken loose. Continue with Step 7 to install a new riv-nut (PN CBX2G093). If there was no problem when removing the sensors, continue with Step 8. 7. Replaced a spun riv-nut as follows: NOTE: The following procedure is applicable for vehicle built at the Windsor Assembly Plant after May 24, 2004 or the St. Louis Assembly Plant after June 28, 2004. Very few vehicles are expected to require riv-nut replacement. a. For vehicles with fog lamps, disconnect the electrical harness connector to the left and right fog lamps. b. Remove the two screws that secure the left and right wheelhouse splash shield to the front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8153 c Carefully separate the lower air dam plastic push retainers from the lower radiator crossmember. d. Partially lower the vehicle. e. Remove the right and left fascia upper bolts from the upper radiator crossmember (Figure 2). f. Pull the wheelhouse shield back from the front fascia and remove the right and left horizontal nuts holding the front fascia to the front lip of the fender (Figure 3) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8154 g. Remove the two vertical screws holding the front fascia to the front fender. h. Carefully remove the front fascia and set it aside. CAUTION: Be careful not to scratch the painted surfaces of the front fascia and the front fenders. i. Break the supplemental front airbag sensor apart using a suitable tool. Remove broken airbag sensor pieces from the vehicle and discard. j. Using a cut-off wheel, cut off the head of the airbag sensor mounting bolt. k. Remove and discard the supplemental front airbag sensor bushing. l. Using a hammer, carefully drive the bolt and the riv-nut into the lower radiator crossmember. CAUTION: Do not distort the structural sheet metal surface where the riv-nut is attached. m. Remove the old riv-nut through the access hole of the lower radiator crossmember using a magnetic tool. NOTE: Be sure to completely remove the riv-nut from the lower radiator crossmember. n. Pre-assemble the new riv-nut by installing the M6 nut and the riv-nut onto the M6 bolt as shown in Figure 4. o. Insert the riv-nut-bolt/nut assembly into the body sheet metal hole. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8155 p. Using a 10 mm crows foot, tighten the installation nut to 80 in. lbs. (9 N.m) while holding the head of the installation bolt stationary (Figure 5). q. Loosen the installation nut and remove the installation bolt and nut from the riv-nut. r. Repeat Steps 7i through 7q for each airbag sensor mounting riv-nut that has broken loose (spins freely). s. Clean the supplemental front airbag sensor mounting surface for both sensors. t. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091: > For sensors fastened with self tapping bolts: a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6. b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts. c. Tightening the self tapping bolts to 60 in.lbs. (7 N.m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8156 > For sensors fastened with M6 bolts and riv-nuts: a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). u. Inspect the right and left supplemental front airbag sensor wiring connectors. If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B Harness Connector Replacement. v. Position the front fascia onto the vehicle. w. Install the right and left upper bolts fascia bolts and tighten to 50 in. lbs. (5 N.m). x. Install the right and left horizontal nuts that fastens the front fascia to the front lip of the front fender. Tighten the nut to 60 in. lbs. (7 N.m). y. Install and tighten the two vertical screws that secure the front fascia to the front fenders. z. Install the two screws that secure the right and left wheelhouse shield to the front fascia. aa. Using new push pins if necessary, install the air dam to the lower radiator crossmember. ab. For vehicles with fog lamps, connect the electrical harness connectors to the fog lamps. ac. Continue with Step 10. 8. Clean the supplemental front airbag sensor mounting surface for both sensors. 9. Install the new supplemental front airbag sensors using the appropriate fasteners included in the Supplemental Front Airbag Sensor Package CBX2G091: > For sensors fastened with self tapping bolts: a. Pre-assemble both supplemental front airbag sensors, bolts, and washers as shown in Figure 6. b. Position the right and left supplemental front airbag sensor on the vehicle and tighten each self tapping bolt into the mounting hole about five turns to cut new threads for the larger M7 self tapping bolts. c. Tightening the self tapping bolts to 60 in. lbs. (7 N.m). > For sensors fastened with M6 bolts and riv-nuts: a. Hand-start the new sensor fastening bolts for the right and left supplemental front airbag sensors into the riv-nuts. b. Tighten the sensor fastening bolts to 60 in. lbs. (7 N.m). 10. Inspect the right and left supplemental front airbag sensor wiring connectors. If there is corrosion (white, green or black) on either terminal of the harness connectors, continue with Section B - Harness Connector Replacement. 11. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector. NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector. 12. Connect harness connectors to the right and left supplemental front airbag sensors. 13. Lower the vehicle. 14. Connect the negative battery cable to the battery. 15. Stand next to the vehicle with the driver¡C■s door closed. Reach in through the window opening, going behind the steering wheel and turn the ignition key to the "ON" position. Wait 10 seconds: > If the airbag warning light is not illuminated the repair has been completed. Return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8157 continue with Step 16 to clear the sensor DTC. 16. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. 17. Turn the ignition key to the "ON" position. 18. Press the "YES" button when the DRBIII powers up. 19. Select "DRBIII STANDALONE" and press "ENTER". 20. Select "1997-2007 DIAGNOSTICS" and press "ENTER". 21. Select "ALL" and press "ENTER" 22. Select "PASSIVE RESTRAINT" and press "ENTER". 23. Select "CLEAR DTCS". 24. Disconnect and remove the DRBIII from the vehicle. B. Airbag Sensor Harness Connector Replacement NOTE: Only those harness connectors that exhibit terminal corrosion, as described in Section A, require replacement. 1. Cut off 3 inches (75 mm) of the old supplemental front airbag sensor wire harness connector as measured from the end of the sensor connector. 2. Remove about 1 inch (25 mm) of black tape from the sensor wire harness. 3. Remove 1/2 inch (13 mm) of insulation from each wire. 4. Cut the new harness connector wires so that the final length is equal to the old harness. 5. Remove 1/2 inch (13 mm) of insulation from each new harness connector wire. 6. Slide one piece of heat shrink tubing onto each of the harness connector wires. 7. Load and center the brass splice band into cavity "B" of the wire splice crimp tool (# 10042) and close the tool just the tool just CAUTION: The crimp jaw must be installed in the crimp tool frame as shown in Figure 7. The crimp jaw wire gauge numbers must be on the same side. When installing the crimp jaw into the tool frame, orient the upper die with the arrow pointed "up" and the lower die with the arrow pointed forward. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8158 8. Match the new harness connector wires to the existing vehicle airbag sensor harness connector wires as follows: > For the right (passenger side) supplemental front airbag sensor, match the new harness connector wire colors to the same color wire on the existing body wire harness. > For the left (driver's side) supplemental front airbag sensor, match the new harness connector wire colors to same tracer (stripe) color wire on the existing body wire harness. CAUTION: Ensure that wire color/polarity is correct. Incorrect wire color/polarity will cause illumination of the airbag warning lamp. warning lamp. 9. Insert the new and existing wire strands (from opposite sides) into the splice band/crimp tool so that they overlap each other inside of the splice band (Figure 8). 10. Crimp the splice band and wires together by squeezing the crimping tool handles. The tool will release once the proper crimping force has been achieved (Figure 8). 11. Solder the connection together using only rosin-core type solder (Figure. 9). CAUTION: DO NOT use acid core solder. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8159 12. Center the heat shrink tubing over the joint and heat using a heat gun. Apply heat to the heat shrink tube until the tubing is tightly sealed and sealant comes out of both ends of the tubing (Figure 10). CAUTION: Use only the sealant lined heat shrink tube provided. Use of electrical tape or non-sealant lined heat shrink may cause circuit failure. 13. Apply a small amount of dielectric grease (PN J8126688) to the right and left supplemental front airbag sensor harness connector. NOTE: Using your finger, force the dielectric grease into the terminal pins of each supplemental front airbag sensor harness connector. 14. Connect harness connectors to the right and left supplemental front airbag sensors. 15. For vehicles with the front fascia removed: a. Position the front fascia onto the vehicle. b. Install the right and left upper fascia bolts and tighten to 50 in. lbs. (5 N.m). c. Install the right and left horizontal nuts that fasten the front fascia to the lip of the front fender. Tighten the nuts to 60 in. lbs. (7 N.m). d. Install and tighten the two vertical screws that secure the front fascia to the front fenders. e. Install the two screws that secure the right and left wheelhouse shield to the front fascia. f. Using new push pins if necessary, securing the air dam to the lower radiator crossmember. g. For vehicles with fog lamps, connect the electrical harness connectors to the right and left fog lamps. 16. Lower the vehicle. 17. Connect the negative battery cable to the battery. 18. Stand next to the vehicle with the driver's door closed. Reach in through the window opening, going behind the steering wheel, and turn the ignition key to the "ON" position. Wait 10 seconds: > If the airbag warning light is not illuminated, the repair has been completed. Return the vehicle to the customer. > If the airbag warning light was illuminated due to a supplemental front airbag sensor fault when the vehicle was brought in for this repair, continue with Step 19 to clear the sensor DTC. 19. Turn the ignition key to the "OFF" position and connect the DRBIII to the vehicle. NOTE: The DRBIII must be at software Version 64.0 or later. 20. Turn the ignition key to the "ON" position. 21. Press the "YES" button when the DRBIII powers up. 22. Select "DRBIII STANDALONE" and press "ENTER". 23. Select "1997-2007 DIAGNOSTICS" and press "ENTER". Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > G09 > Jun > 07 > Recall - Front Air Bag Impact Sensor Replacement > Page 8160 24. Select "ALL" and press "ENTER". 25. Select "PASSIVE RESTRAINT" and press "ENTER". 26. Select "CLEAR DTCS". 27. Disconnect and remove the DRBIII from the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Impact Sensor: > NHTSA07V192000 > May > 07 > Recall 07V191000: Air Bag Impact Sensor Replacement Impact Sensor: All Technical Service Bulletins Recall 07V191000: Air Bag Impact Sensor Replacement MAKE/MODELS: MODEL/BUILD YEARS: Chrysler/Town & Country 2005 Dodge/Caravan 2005 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 07V192000 MFR'S REPORT DATE: May 01, 2007 COMPONENT: Air Bags: Frontal: Sensor/Control Module POTENTIAL NUMBER OF UNITS AFFECTED: 270958 SUMMARY: Certain minivans are being recalled that were originally sold in or currently registered in the 27 states plus The District of Columbia that use greater amounts of salt for Winter road deicing. The Up-Front (UF) air bag sensors that contain brass bushings installed in these vehicles may corrode and crack allowing water to enter the sensor. These sensors provide enhanced air bag performance in certain types of frontal crashes. CONSEQUENCE: In one of these crashes, with one or both of the vehicle the vehicle's UF sensors inoperative, the occupants will not benefit from the enhanced air bag protection that these sensors would provide. REMEDY: For vehicles registered in the recall states, dealers will replace the original UF air bag sensors with ones with greater corrosion resistance. Vehicles registered in other states will obtain a lifetime free replacement of any UF sensor that fails. The campaign is expected to begin during July 2007. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler's campaign Nos. G09/X16. DaimlerChrysler has not decided that this is a defect related to motor vehicle safety. However, it has informed NHTSA that it will provide the modifications described above free of charge. Customers also may contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline aT 1-888-327-4236 (TTY: 1-800-424-9153); or go to http://www.safercar.gov. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Component Locations Impact Sensor: Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Component Locations > Page 8167 Impact Sensor: Connector Locations Left Fender Shield Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Component Locations > Page 8168 Right Side Body RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Component Locations > Page 8169 Right B Pillar Left B Pillar Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Component Locations > Page 8170 Left Rear Body Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Component Locations > Page 8171 Right Quarter Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 8172 Impact Sensor: Diagrams Left Front Impact Sensor (Except Export Early Build) Left Front Impact Sensor (Export Early Build) Left Side Impact Sensor 1 (Except Export Early Build) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 8173 Left Side Impact Sensor 1 (Export Early Build) Left Side Impact Sensor 2 Left Side Impact Sensor 3 (Except Export Late Build) Left Side Impact Sensor 3 (Export Late Build) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 8174 Right Front Impact Sensor Right Side Impact Sensor 1 (Except Export Early Build) Right Side Impact Sensor 1 (Export Early Build) Right Side Impact Sensor 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 8175 Right Side Impact Sensor 3 (Except Export Late Build) Right Side Impact Sensor 3 (Export Late Build) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Front Impact Sensors Impact Sensor: Description and Operation Front Impact Sensors Front Impact Sensor There are two front impact sensors, one on the left, and one on the right front sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). The right and left front and side impact sensors are identical in construction and calibration and each front impact sensor is secured with two screws. The front impact sensors are secured with two screws to the outboard sides of the right and left front rail tips. The impact sensor housing has an integral connector and two mounting ears, each with a metal sleeve to provide crush protection. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through the headlamp to dash wire harness. The front impact sensors cannot be repaired or adjusted and, if damaged or faulty, they must be replaced. If a front impact sensor is faulty, only the sensor needs to be replaced. If the sensor is damaged or faulty, or if proper tightening torque of the screws that secure the sensor to the bracket cannot be achieved, the sensor and bracket must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Front Impact Sensors > Page 8178 Impact Sensor: Description and Operation Side Impact Sensors Side Impact Sensor Side Impact Sensor Location Three side impact sensors are used on each side of the vehicle. These sensors are mounted remotely from the bi-directional safing sensor that is internal to the Occupant Restraint Controller (ORC). The side and front impact sensors are identical in construction and calibration and each impact sensor is secured with two screws. Each side impact sensor is secured with two screws. The first row side impact sensor is located in the B-pillar, just above the front seat belt retractor. The second row side impact sensor is located in the sliding door opening, in the lower door track area. The third row side impact sensor is located behind the quarter trim panel, above the rear tire wheel well, between the C and D-pillars. The impact sensor housing has an integral connector. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a connector of the body harness. The side impact sensors cannot be repaired or adjusted. If damaged or faulty, they must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor Impact Sensor: Service and Repair Front Impact Sensor REMOVAL. The right and left front impact sensors are mounted identically on the front rail tips. 1. Open hood, disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG SYSTEM OR COMPONENT SERVICE. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, PERSONAL INJURY OR DEATH. 2. Hoist vehicle. Front Impact Sensor Remove/Install 3. Disconnect electrical connector. 4. Remove the two screws attaching front impact sensor to outer rails. 5. Remove sensor from vehicle. INSTALLATION 1. Position sensor in vehicle. 2. Install the two retaining screws to the impact sensor. Torque screws to 7 Nm (62 in. lbs.). 3. Connect electrical connector. 4. Lower vehicle from hoist. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. 5. Verify vehicle and system operation. 6. Close hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor > Page 8181 Impact Sensor: Service and Repair Side Impact Sensors B-Pillar Mounted REMOVAL The right and left front row side impact sensors, are mounted identically, on opposite sides of the vehicle, in the b-pillar. 1. Open hood, disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG COMPONENT SERVICE. PERSONAL INJURY OR DEATH MAY RESULT. 2. Remove the B-pillar lower trim for the side of the vehicle that you are replacing the side impact sensor. Front Row Side Impact Sensor And Bracket 3. Disconnect the electrical connector from the impact sensor. 4. Remove the four retaining screws to the impact sensor bracket. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor > Page 8182 Front Row Side Impact Sensor/Bracket 5. Remove impact sensor from vehicle. INSTALLATION 1. Position sensor bracket in vehicle. 2. Install the four retaining screws to the impact sensor bracket. Torque screws to 7 Nm (62 in. lbs.). 3. Connect the electrical connector. 4. Install the B-pillar lower trim for the side of the vehicle that you are replacing the side impact sensor. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. 5. Verify vehicle and system operation. 6. Close hood. Sliding Door Opening Mounted REMOVAL The right and left second row side impact sensors, are mounted identically, on opposite sides of the vehicle, in the sliding door opening lower rear where the lower roller arm mounts in the lower door track. 1. Open hood, disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG COMPONENT SERVICE. PERSONAL INJURY OR DEATH MAY RESULT. 2. Open sliding door to the fullest open position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor > Page 8183 2nd Row Side Impact Sensor 3. Remove the two retaining screws to the impact sensor. 4. Disconnect the electrical connector from the impact sensor and remove from vehicle. INSTALLATION 1. Connect electrical connector. 2. Position sensor in vehicle. 3. Install the two retaining screws to the impact sensor. Torque screws to 7 Nm (62 in. lbs.). WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. 4. Verify vehicle and system operation. 5. Close hood. Quarter Panel Mounted REMOVAL 1. Open hood, disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG COMPONENT SERVICE. PERSONAL INJURY OR DEATH MAY RESULT. 2. Remove the quarter trim panel for the side of the vehicle that you are replacing the side impact sensor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Front Impact Sensor > Page 8184 3rd Row Side Impact Sensor 3. Remove the two retaining screws to the impact sensor. 4. Disconnect the electrical connector from the impact sensor and remove from vehicle. INSTALLATION 1. Position sensor in vehicle. 2. Connect electrical connector. 3. Install the two retaining screws to the impact sensor. Torque screws to 7 Nm (62 in. lbs.). 4. Install the quarter trim panel for the side of the vehicle that you are replacing the side impact sensor. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. 5. Verify vehicle and system operation. 6. Close hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 8188 Seat Belt Buckle Switch: Diagrams Driver Seat Belt Switch Passenger Seat Belt Switch (Early Build Occupant Sensing) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Tension Sensor > Component Information > Description and Operation Seat Belt Tension Sensor: Description and Operation Belt Tension Sensor Belt Tension Sensor Location Vehicles equipped with the Occupant Classification System (OCS) include a belt tension sensor. This sensor is integral to the passenger side front seat belt lower anchor which is secured to the lower B-pillar, on the passenger side. The belt tension sensor consists of a molded plastic housing, a metal seat belt anchor loop, and a short pigtail wire. The electronic circuitry of the belt tension sensor is concealed and protected within the molded plastic housing. The belt tension sensor cannot be repaired and, if faulty or damaged, the entire passenger side front seat belt and retractor unit must be replaced. The belt tension sensor is designed to sense the relative cinch load applied to the passenger side front seat belt, which provides a logic input to the microprocessor of the Occupant Classification Module (OCM). When a load is applied to the seat belt, the changes in the load are measured by the belt tension sensor through the seat belt lower anchor. As the load changes, the circuitry of the belt tension sensor changes the output voltage of the sensor. The belt tension sensor receives a nominal five volts and a ground from the OCM. The OCM then monitors the belt tension sensor output voltage. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Tension Sensor > Component Information > Description and Operation > Page 8192 WARNING: DO NOT CONNECT THE BATTERY BEFORE PERFORMING THE OCS VERIFICATION TEST USING THE SCAN TOOL AND THE APPROPRIATE DIAGNOSTIC INFORMATION. PERSONAL INJURY OR DEATH MAY OCCUR. For further diagnosis and testing of the belt tension sensor, the OCM, and related occupant classification system components, use a scan tool and the appropriate diagnostic information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Diagrams Seat Occupant Sensor: Diagrams Passenger Seat Weight Sensor Occupant Classification Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams Passenger Seat Weight Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Diagrams > Page 8199 Seat Sensor/Switch: Description and Operation Seat Weight Bladder And Pressure Sensor - Typical Vehicles equipped with the Occupant Classification System (OCS) have a seat weight bladder and pressure sensor unit that is integral to the passenger front seat cushion. The bladder is sandwiched between the seat cushion pan and seat cushion foam. The bladder consists of two rectangular sheets of an elastomeric material and a molded plastic elbow fitting. The two sheets of material are sealed together around their perimeter and heat staked to each other at numerous regular points within their field. The elbow fitting is sealed to a small round hole in the lower surface of the bladder and is pointed downward where it passes through a clearance hole in the insulator pad and extends to just below the seat cushion. The bladder is then filled with a silicone fluid to become a pliable, quilted membrane. Under the seat cushion a short tube is securely clamped at one end to the bladder nipple, and at the other end to a nipple on the electronic pressure sensor. The sensor housing features an integral mount that snaps over a tab integral to the stamped steel Occupant Classification Module (OCM) mounting bracket welded to the underside of the passenger front seat cushion frame. The seat weight bladder and pressure sensor cannot be adjusted or repaired. The components of the passenger front seat cushion of a vehicle equipped with the OCS including the cushion frame, seat weight bladder and pressure sensor, seat cushion foam, wire harness and the OCM are serviced only as a factory-calibrated, assembled and tamper-evident unit. Only the OCM and the seat cushion trim are available for separate service replacement. Once a service replacement package has been installed in a vehicle, the OCM can thereafter be serviced only by replacing the entire passenger front seat cushion unit with another complete service replacement package. The seat weight bladder and pressure sensor unit is designed to sense the relative weight of a load applied to the passenger front seat cushion, which provides a logic input to the microprocessor of the Occupant Classification Module (OCM). When a load is applied to the seat cushion, fluid within the bladder becomes pressurized. These changes in bladder fluid pressure are measured by the pressure sensor under the seat cushion through the bladder tube. As the pressure within the bladder changes, the circuitry of the pressure sensor changes the output voltage of the sensor. The pressure sensor receives a nominal five volts and a ground through hard wired circuits from the OCM. The OCM then monitors the pressure sensor output voltage on the Programmable Communication Interface (PCI) data bus circuit. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8205 Accessory Delay Relay: Description and Operation ACCESSORY RELAY The accessory relay is an electromechanical device that switches fused battery current to the accessory powered vehicle circuits when the ignition switch is turned to the Accessory or ON positions. The delay feature will maintain power to the accessories for 45 seconds after the ignition is shut OFF or until a door is opened. This allows sufficient time to close windows and park the windshield wipers. The accessory relay is located in the Integrated Power Module (IPM) in the engine compartment. The accessory relay is a International Standards Organization (ISO) relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The accessory relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Description and Operation Antenna Control Module: Description and Operation The antenna module is an electromagnetic circuit component designed to capture and enhance RF (Radio Frequency) signals in both the AM and FM broadcast bands. The antenna module is mounted to the right rear roof rail under the headliner. The module is grounded through the mounting bracket and fastener. The module has a two wire electrical connector that connects to the integral radio antenna,located on the right rear quarter glass. There is also an electrical connector for battery voltage and a coax cable connector. The antenna module receives both AM and FM radio signals supplied by the side window integral radio antenna system and selectively amplifies them. The amplified signal is then sent through the body length coax cable to the radio input. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Description and Operation > Page 8210 Antenna Module - Export Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Description and Operation > Page 8211 Antenna Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Antenna Module 2. Lower headliner as necessary to access antenna module. 3. Disconnect antenna coax cable lead and electrical harness connector from antenna module. 4. Disconnect the antenna module connector from the quarter glass. 5. Remove the mounting screw and the antenna module. INSTALLATION 1. Install the antenna module and the mounting fastener. 2. Connect the antenna connector to the quarter glass. 3. Connect the antenna lead and electrical connector to the antenna module. 4. Raise and install headliner. 5. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Audio System - Revised Antenna Mast Installation Antenna Mast: Technical Service Bulletins Audio System - Revised Antenna Mast Installation NUMBER: 08-058-05 GROUP: Electrical DATE: October 29, 2005 SUBJECT: Revised Radio Antenna Mast Installation Procedure MODELS: 2005 - 2006 (DR/DH/D1) Ram Truck 2005 - 2006 (HB) Durango 2005 - 2006 (ND) Dakota 2005 - 2006 (PL) Neon 2005 - 2006 (PT) PT Cruiser 2005 - 2006 (RS) Town & Country/Caravan DISCUSSION: The installation procedure for the radio antenna mast has been revised. Please use the following procedure when installing the antenna mast to the antenna base. CAUTION: Do not exceed the torque specification in the step below. Damage to the antenna mast and/or base may occur if the tightening torque is exceeded. 1. Install antenna mast to antenna base. Finger tighten the antenna mast until it is fully seated on antenna base; no gap between the mast and base. Using a torque wrench, tighten the antenna mast to 3.4 - 3.6 N.m (30 - 32 in.lbs.) (Fig. 1). POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair Antenna, Navigation: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the radio. Navigation Antenna Navigation Antenna Mounting 3. Disconnect antenna from radio. Remove tape securing antenna to air duct, and remove antenna. INSTALLATION 1. Secure antenna to air duct. 2. Connect antenna to radio. 3. Install radio. 4. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Horn > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Horn > Component Information > Locations > Page 8223 Siren (United Kingdom) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams Thatcham Alarm Module (united Kingdom) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 8227 Alarm Module: Service and Repair PROGRAMMING THE SENTRY KEY REMOTE ENTRY MODULE NOTE: If the PCM and the SKREEM are replaced at the same time program the VIN into the PCM first. All vehicle keys will then need to be replaced and programmed to the new SKREEM. 1. Turn the ignition on (transmission in park/neutral). 2. Use the DRBIII(R) and select THEFT ALARM SKREEM then MISCELLANEOUS. 3. Select SKREEM MODULE REPLACEMENT (GASOLINE). 4. Program the vehicle four-digit PIN into the SKREEM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKREEM the SKREEM must be replaced. 6. Select UPDATE VIN (the SKREEM will learn the VIN from the PCM). 7. Press ENTER to transfer the VIN (the PCM will send the VIN to the SKREEM). 8. The DRBIII(R) will ask if you want to transfer the secret key. Select ENTER to transfer secret key from the PCM. This will ensure the current vehicle ignition keys will still operate the SKREES system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation Alarm System Transponder: Description and Operation The Sentry Key Remote Entry System (SKREES) uses a transponder chip that is integral to the circuit board of the integrated ignition key (SKREES and RKE incorporated) to communicate with the Sentry Key Remote Entry Module (SKREEM). Ignition keys are supplied with the vehicle when it is shipped from the factory. For export vehicles equipped with SKREES, the transponder chip is undermolded within the head of the key. Each Sentry Key has a unique transponder identification code permanently programmed into it by the manufacturer. Likewise, the Sentry Key Remote Entry Module (SKREEM) has a unique "Secret Key" code programmed into it by the manufacturer as well. When a Sentry Key is programmed into the memory of the SKREEM, the SKREEM stores the transponder identification code from the Sentry Key, and the Sentry Key learns the "Secret Key" code from the SKREEM. Once the Sentry Key learns the "Secret Key" code of the SKREEM, it is also permanently programmed into the transponder's memory. Therefore, blank keys for the Sentry Key Remote Entry System (SKREES) must be programmed by the SKREEM in addition to being cut to match the mechanical coding of the ignition lock cylinder. The Sentry Key's transponder is within the range of the SKREEM's transceiver antenna ring when it is inserted into the ignition lock cylinder. When the ignition switch is turned to the ON position, the SKREEM communicates with the Sentry Key via a radio frequency (RF) signal. The SKREEM determines if a valid key is present based on the information it receives from the Sentry Key. If a valid key is detected, that fact is communicated to the PCM via the PCI bus and the vehicle is allowed to continue running. If an invalid key is received by the PCM or no status at all is communicated, the vehicle will stall after two (2) seconds of running. The indicator light will be flashing at this point. The Sentry Key's transponder can not be repaired. If it is faulty or damaged, it must be replaced. Common communication problems: - Two transponder keys too close together. - Speed Pass too close to transponder key. Solid indicator that there is a system failure. - Loss of PCM communication. - Failed antenna circuit. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation > Page 8231 Alarm System Transponder: Testing and Inspection USING A DRBIII (R) SCAN TOOL All Sentry Keys included with the vehicle are preprogrammed to work with the Sentry Key Remote Entry System (SKREES) when it is shipped from the factory. The Sentry Key Remote Entry Module (SKREEM) can be programmed to recognize up to a total of eight Sentry Keys. When programming a blank Sentry Key transponder, the key must first be cut to match the ignition lock cylinder of the vehicle for which it will be used. The vehicle's four digit PIN code will be required to complete this task since you will need it to enter the Secured Access Mode in the SKREEM. The following steps must be completed using a DRBIII (R) scan tool: 1. Insert the blank key into the ignition and turn it to the RUN position. 2. Using a DRBIII« scan tool, select "Theft Alarm," "SKREEM," "Miscellaneous," and then "Program New Key." 3. Enter the four digit PIN code using the DRBIII« scan tool. When programming is completed, the SKREEM will exit Secured Access Mode and the DRBIII« scan tool will display the results of your attempt to program the key. One of five distinct results may be displayed. All five are listed below: "Programming Successful" is displayed if the Sentry Key programming is successful. - "Learned Key in Ignition" is displayed if the key in the ignition has already been programmed into that vehicle's SKREEM. - "Eight Keys Already Learned (At The Maximum) Programming Not Done" is displayed if eight keys have already been programmed into the SKREEM. In this case, if a new key needs to be added due to a lost or defective key, the "Erase All Keys" command (which requires entering the Secured Access Mode) has to be performed. Following the "Erase All Keys" command, all keys that will be used to operate the vehicle MUST be reprogrammed to the SKREEM. - "Programming Not Attempted" is displayed after an "Erase All Keys" function is executed. - "Programming Key Failed" is displayed if further diagnosis is required. To learn additional keys, turn the ignition OFF, remove the learned key, insert the next new blank key, and repeat the steps from the beginning. " CUSTOMER LEARN' MODE This feature is only available on domestic vehicles or those which have a U.S. country code designator. This procedure requires access to at least two valid Sentry Keys. If two valid Sentry Keys are not available, Sentry Key programming will require the use of a DRBIII« scan tool. The steps required to program Sentry Keys with two valid Sentry Keys follows: 1. Obtain the blank Sentry Key(s) that need to be programmed. Cut the keys to match the ignition lock cylinder mechanical key codes. 2. Insert one of the two valid Sentry Keys into the ignition switch and turn the ignition switch to the ON position. 3. After the ignition switch has been in the ON position for longer than three seconds, but no more than fifteen seconds, cycle the ignition switch back to the OFF position. Replace the first valid Sentry Key in the ignition lock cylinder with the second valid Sentry Key and turn the ignition switch back to the ON position. The second valid Sentry Key must be inserted within 15 seconds of removing the first valid Sentry key. 4. About ten seconds after the completion of Step 3, the indicator light will start to flash and a single audible chime tone will sound to indicate that the system has entered the "Customer Learn" programming mode. 5. Within sixty seconds of entering the "Customer Learn" programming mode, turn the ignition switch to the OFF position, replace the valid Sentry Key with a blank Sentry Key transponder, and turn the ignition switch back to the ON position. 6. About ten seconds after the completion of Step 5, a single audible chime tone will sound and the indicator light will stop flashing and stay on solid for three seconds and then turn off to indicate that the blank Sentry Key has been successfully programmed. The SKREES will immediately exit the "Customer Learn" programming mode and the vehicle may be started using the newly programmed Sentry Key. NOTE: The Remote Keyless Entry (RKE) Transmitter will also be programmed during this procedure. These steps must be completed in their entirety for each additional Sentry Key to be programmed. If any of the above steps are not completed in the given sequence, or within the allotted time, the SKREES will exit the "Customer Learn" programming mode and the programming will be unsuccessful. The SKREES will also automatically exit the "Customer Learn" programming mode if: - It sees a non-blank Sentry Key when it should see a blank. - If it has already programmed four 4. valid Sentry Keys. - If the ignition switch is turned to the OFF position for more than about fifty (50) seconds. NOTE: - If you attempt to start the vehicle while in "Customer Learn" mode (LED flashing), the vehicle will behave as though an invalid key is being used (i.e. the engine will stall after two (2) seconds of running). No faults will be logged. - Once a Sentry Key has been programmed to a particular vehicle, it cannot be used on any other vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component Locations Hood Sensor/Switch (For Alarm): Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component Locations > Page 8236 Left Side Engine Compartment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 8237 Hood Sensor/Switch (For Alarm): Service and Repair HOOD AJAR SWITCH-EXPORT REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a small flat blade screwdriver, pry trigger switch from the bracket on the left fender well. 3. Disconnect the hood ajar switch from the wire connector and remove from vehicle. INSTALLATION 1. Connect the hood ajar switch to the wire connector. 2. Press the hood ajar switch into position on the bracket located on the left inner fender well. 3. Reconnect the battery negative cable. 4. Close the hood and check for proper operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Ignition Shut Down Relay (For Antitheft) > Component Information > Description and Operation Ignition Shut Down Relay (For Antitheft): Description and Operation AUTO SHUT DOWN RELAY The relay is located in the Power Distribution Center (PDC). For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary The engine switched battery (NGC vehicles) informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is also used to power certain drivers on NGC vehicles. When energized, the ASD relay on NGC vehicles provides power to operate the injectors, ignition coil, generator field, O2 sensor heaters (both upstream and downstream), evaporative purge solenoid, EGR solenoid (if equipped) wastegate solenoid (if equipped), and NVLD solenoid (if equipped). The ASD relay also provides a sense circuit to the PCM for diagnostic purposes. If the PCM does not receive 12 volts from this input after grounding the control side of the ASD relay, it sets a Diagnostic Trouble Code (DTC). The PCM energizes the ASD any time there is an engine speed that exceeds a predetermined value (typically about 50 rpm). The ASD relay can also be energized after the engine has been turned off to perform an O2 sensor heater test, if vehicle is equipped with OBD II diagnostics. As mentioned earlier, the PCM energizes the ASD relay during an O2 sensor heater test. On NGC vehicles it checks the O2 heater upon vehicle start. The PCM still operates internally to perform several checks, including monitoring the O2 sensor heaters. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations > Page 8246 Keyless Entry Module: Connector Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations > Page 8247 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations > Page 8248 Steering Column Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations > Page 8249 Center Instrument Panel Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations > Page 8250 Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 8251 Sentry Key Remote Entry Module (Skreem) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 8252 Keyless Entry Module: Description and Operation The Sentry Key Remote Entry Module (SKREEM) performs the functions of the Sentry Key Immobilizer Module (SKIM), Remote Keyless Entry (RKE) Module, and the Tire Pressure Monitoring (TPM) System (previously part of the Electronic Vehicle Information Center (EVIC). The SKREEM is located in the same location as the SKIM was and is mounted the same way. It looks identical, but has added capabilities. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 8253 Keyless Entry Module: Testing and Inspection For proper diagnosis and testing of the Sentry Key Remote Entry Module (SKREEM), use a DRBIII (R) and refer to the proper Body Diagnostic Procedures information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 8254 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the Steering Column Opening Cover. 3. Remove the steering column upper and lower shrouds. 4. Disengage the steering column wire harness from the Sentry Key Remote Entry Module (SKREEM). 5. Remove the one screws securing the SKREEM to the steering column. 6. Rotate the SKREEM upwards and then to the side away from the steering column to slide the SKREEM antenna ring from around the ignition switch lock cylinder housing. 7. Remove the SKREEM from the vehicle. INSTALLATION 1. Slip the Sentry Key Remote Entry Module (SKREEM) antenna ring around the ignition switch lock cylinder housing. Rotate the SKREEM downwards and then towards the steering column. 2. Install the one screws securing the SKREEM to the steering column. 3. Connect the steering column wire harness to the SKREEM. 4. Install the steering column upper and lower shrouds. 5. Install the Steering Column Opening Cover. 6. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Specifications Keyless Entry Transmitter Battery: Specifications BATTERY The batteries can be removed without special tools and are readily available at local retail stores. The recommended battery is Duracell DL 2016 or equivalent, TWO cells are required. Battery life is about three years minimum. CAUTION: Do not touch the battery terminals or handle the batteries any more than necessary. Hands must be clean and dry. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Specifications > Page 8259 Keyless Entry Transmitter Battery: Service and Repair BATTERY REPLACEMENT 1. With the transmitter buttons facing down, use a coin to pry the two halves of the transmitter apart. Make sure not to damage the rubber gasket during separation of the housing halves. 2. Remove the battery from the transmitter back housing holder. 3. Replace the batteries. Avoid touching the new batteries with your fingers, Skin oils may cause battery deterioration. If you touch a battery, clean it off with rubbing alcohol. 4. To assemble the transmitter case, snap the two halves together. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations Lock Cylinder Switch: Locations Driver Door Passenger Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Locations > Page 8263 Right Cylinder Lock Switch (Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Description and Operation Security Lamp/Indicator: Description and Operation The Sentry Key Remote Entry System (SKREES) uses an indicator light to convey information on the status of the system to the customer. This light is shared with the Vehicle Theft Security System (VTSS). The light is located in the Mechanical Instrument Cluster (MIC). The VTSS status is controlled by the Body Control Module (BCM), via Programmable Communication Interface (PCI) data bus communication with the MIC, based upon messages it receives from the Sentry Key Remote Entry Module (SKREEM) on the PCI data bus. The Mechanical Instrument Cluster (MIC) performs a four second bulb check via PCI communication with the Sentry Key Remote Entry Module (SKREEM). After the bulb check, the lamp is controlled according to SKREEM messages. Then, the SKREEM sends messages to the BCM to operate the light based upon the results of the Sentry Key Remote Entry System (SKREES) self tests. The light may be actuated in two possible ways, flashing or on solid. If the light comes on and stays on solid after a power-up test, this indicates that the SKREEM has detected a system malfunction. If the SKREEM detects an invalid key when the ignition switch is moved to the ON position, it sends a message on the PCI bus to the MIC, to flash the light. The SKREEM can also send a message to flash the light and generate a single audible chime at the same time. These two events occurring simultaneously indicate that the SKIS has been placed into the "Customer Learn" mode. If the light comes on and stays on after the power-up test, diagnosis of the SKREES should be performed using a DRBIII (R) scan tool and the appropriate Body Diagnostic Procedures information. The light is a Light Emitting Diode (LED) and is not a serviceable component. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Ultrasonic Sensor, Antitheft > Component Information > Locations Ultrasonic Sensor: Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Ultrasonic Sensor, Antitheft > Component Information > Locations > Page 8270 Ultrasonic Sensor: Diagrams Front Intrusion Sensor (United Kingdom) Rear Instrusion Sensor (United Kingdom) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Cell Phone - UConnect(R) Hands Free Phone Inoperative Cellular Phone: Technical Service Bulletins Cell Phone - UConnect(R) Hands Free Phone Inoperative NUMBER: 08-013-05 REV. A GROUP: Electrical DATE: October 1, 2005 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-013-05, DATED FEBRUARY 16, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED DISCUSSION. SUBJECT: UConnect Hands Free Phone Inoperative OVERVIEW: This bulletin directs the technician to the appropriate diagnostic path by vehicle line. MODELS: 2005 - 2006 (CS) Pacifica 2005 - 2006 (DR/DH) Ram Truck/Ram Truck HD 2005 - 2006 (HB) Durango 2005 - 2006 (KJ) Liberty 2005 - 2006 (LX) 300/Magnum/Charger 2005 - 2006 (ND) Dakota 2005 - 2006 (PT) PT Cruiser 2005 - 2006 (RS) Town & Country/Caravan 2005 - 2006 (WK) Grand Cherokee NOTE: This bulletin applies to vehicles equipped with UConnect(TM) Hands Free Communications (sales code RSP). **DISCUSSION: NOTE: Verify that service bulletin 08-049-05 has been performed (where applicable) before proceeding further with this bulletin. NOTE: On CS vehicles with a 05091004AL UConnect Hands Free Module, the scan tool may display a $21 - Bus Busy DTC. This DTC is erroneous and should be ignored. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical Service Bulletins > Cell Phone - UConnect(R) Hands Free Phone Inoperative > Page 8275 If the UConnect Hands Free Phone is inoperative and if there are no DTC's, perform the existing diagnostic procedure available in TechCONNECT as described in the table. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Connector Views Cellular Phone: Connector Views C206 (DVD/Hands Free) C207 (Hands Free) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Diagrams > Page 8278 Cellular Phone: Description and Operation HANDS FREE PHONE OVERVIEW The vehicle telecommunications system consists of a Hands Free Module, Rear View Mirror, and a Blue-tooth Hands Free Profile enabled cell phone. The system allows vehicle occupants to use voice recognition technology to make, receive and screen phone calls without physically handling a cell phone. The system has a programmable phone book that can prevent the vehicle operator from becoming distracted searching for a specific number. Seven different wireless phones can be programmed to operate each individual system. Each of the seven phones is given a rank of priority when programmed. OPERATION Incoming phone messages are transmitted to the vehicle occupants through the vehicles audio system when the ignition is on and the wireless phone is on. Upon receiving the signal from an incoming phone call, the vehicle audio system will fade out the current CD/DVD or radio output. The vehicle occupants are then directed to accept or reject the call.Outgoing audio messages are received through the microphone located in the rearview mirror then transmitted via hardwire to the Hands Free Module and finally transmitted through the wireless phone. Volume of the voice prompts and incoming conversation is controlled using the vehicles radio audio controls and steering wheel controls if equipped. The rear view mirror contains a Phone Switch, Voice Recognition Switch and a microphone. The rear view mirror transmits these inputs via hardwired circuits to the Hands Free Module. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations Left Rear Body Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8283 Park Assist Module (Parktronics) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8284 Parking Assist Control Module: Description and Operation Park Assist Module Park Assist Module - Location The Park Assist Module is located on the left side of the vehicle, behind the quarter trim panel, just behind the C-pillar. It is has a molded plastic housing which housing internal circuitry and one electrical connector. There are two mounting tabs that affix the module to the left inner quarter panel with two screws. The module has a number of functions: - Supply voltage to the sensors and display. - Disconnection of the display with bus idle and over voltage Vmax. - Triggering the sensors. - Analyze echo delay times and calculate obstacle distances. - Bi-directional data communication to the display for diagnosis. - System diagnostics - diagnosis and error handling (sensors, display, module). - Data exchange over the Programmable Communication Interface (PCI) data bus. The module has a number of functions: - Supply voltage to the sensors and display. - Disconnection of the display with bus idle and over voltage Vmax. - Triggering the sensors. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8285 - Analyze echo delay times and calculate obstacle distances. - Bi-directional data communication to the display for diagnosis. - System diagnostics - diagnosis and error handling (sensors, display, module). - Data exchange over the Programmable Communication Interface (PCI) data bus. The system detection length from the rear of the vehicle is 0.3 meters to 1.5 meters. This area extends around the rear side of the vehicle. The system detection height from the ground is 0.2 meters to about 1.5 meters. The radio mutes when the system activates its audible tone. When the driver selects Reverse, the system scans for objects behind the vehicle using four sensors located in the rear bumper. Objects can be detected from up to 1.5 meters. A warning display above the rear window provides both visible and audible warnings indicating the range of the object. The system is active only when the vehicle is in reverse for vehicle speeds less than 16 Km/h (10 mph). If the vehicles Parking/Emergency Brake is applied, the system is deactivated. The display contains two sets of yellow and red Light Emitting Diode's (LED's) that the driver can see as they look over their shoulder while backing up. Each side of the vehicle has its own warning LED's. The system provides a visual warning by illuminating one or more yellow LED's as the vehicle gets closer to the object. As the vehicle continues to approaches the object, one red LED is illuminated and the system emits a series of short beeps. The tone will remain constant and both red LED's are illuminated once the vehicle is within 12 inches (30.5 cm) of the object. The system can be turned ON or OFF through the Electronic Vehicle Information Center (EVIC) when the vehicle is in PARK. If the park assist system is turned OFF, a single chime will sound and the EVIC will display the following message "REAR PARK ASSIST OFF", when the vehicle is in reverse. - Ensure that the rear bumper is free of dirt and debris to keep the system operating properly. - Jackhammers, large trucks, and other vibrations could affect the performance of the system. - Ensure that the parking brake is not applied. If "Service Park Assist System" appears in the EVIC after making sure the rear bumper is clean, proceed to diagnose the system using a scan tool and the appropriate diagnostic information. To diagnose the Park Assist Module, use a scan tool and the appropriate body diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations > Page 8286 Parking Assist Control Module: Service and Repair REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Remove the left quarter trim panel. Park Assist Module Electrical Connector 4. Disconnect the Park Assist Module electrical connector. Park Assist Module Location 5. Remove the two attaching screws and separate the module from vehicle. INSTALLATION 1. Position the Park Assist Module and install the two attaching screws. Torque screws to 3.5 Nm (30 in. IDS.). 2. Connect the Park Assist Module electrical connector. 3. Install the left quarter trim panel. 4. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams Parking Assist Distance Sensor: Diagrams Park Assist Sensor No.7 (Parktronics) Park Assist Sensor No.8 (Parktronics) Park Assist Sensor No.9 (Parktronics) Park Assist Sensor No.10 (Parktronics) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 8290 Parking Assist Distance Sensor: Description and Operation Park Assist Sensor Park Assist Sensor Location The Park Assist Sensors are located in the rear bumper fascia mounted equally apart. The sensors generate ultrasonic pulses when triggered by the park assist module when an obstacle is detected. The sensors then signal the module when reflected ultrasonic pulses are received. The sensors detect objects with an ultrasonic pulse that reflects off the object and then is sent to the module to determine the distance of the object. The Park Assist Sensors: - Generate ultrasonic pulses when triggered by the Park Assist Module. - Reception/filtering of ultrasonic energy received. - Signalling the module of received ultrasonic pulses that meet threshold criteria. The sensors are supplied power by the module. The sensor supply is enabled when the sensor function is necessary. The sensors detection length from the rear of the vehicle is 0.3 meters to 1.5 meters. This area extends around the rear side of the vehicle. The sensor detection height from the ground is 0.2 meters to about 1.5 meters. - Ensure that the rear bumper (sensors) is free of dirt and debris to keep the system operating properly. - Jackhammers, large trucks, and other vibrations could affect the performance of the system. - Ensure that the parking brake is not applied. If "Service Park Assist System" appears in the EVIC after making sure the rear bumper is clean, proceed to diagnose the system using a scan tool and the appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Page 8291 Parking Assist Distance Sensor: Service and Repair REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Remove rear fascia. Sensor Retaining Clip 4. Remove the sensor retaining clip from the back side of the fascia. Sensor - Remove/Install 5. Push the Park Assist Sensor out of the fascia. INSTALLATION 1. Position the Park Assist Sensor over the retaining housing and firmly snap into housing in rear fascia. 2. Install the rear fascia. 3. Connect the battery negative cable. 4. Close hood. 5. Verify vehicle and system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8297 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8298 Figure 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8299 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8300 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8301 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8302 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8303 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8304 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8305 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8306 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8307 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8308 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8309 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8310 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8311 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8312 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8313 Driver/Vehicle Information Display: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and an Electrostatic Discharge Symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8314 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8315 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8316 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8317 Message Center (Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console Driver/Vehicle Information Display: Description and Operation Overhead Console OVERHEAD CONSOLE Three overhead consoles options are available on this vehicle. These options are: - The Electronic Vehicle Information Center (EVIC) - The Compass Mini-Trip Computer (CMTC) All consoles are equipped with two reading/courtesy lamps and if the vehicle is equipped with a power liftgate or power sliding door(s) the overhead console will also include switches for these features. The overhead console is mounted with one screw and two snap clips to a molded plastic retainer bracket located above the headliner. COMPASS All overhead consoles include compass information. While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may be necessary is to drive the vehicle in three complete circles at 5 to 8 kilometers-per-hour (3 to 5 miles-per-hour), on level ground, for a minimum of forty-eight seconds. This will reorient the compass unit to its vehicle. The compass unit will also compensate for magnetism the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. The use of magnetic tools on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the compass operation is erratic and roof magnetization is suspected, refer to Compass Demagnetizing. See: Instrument Panel, Gauges and Warning Indicators/Compass/Service and Repair/Compass Demagnetizing TEMPERATURE All overhead consoles include temperature information. The temperature displays the outside ambient temperature in whole degrees. The temperature display can be toggled from Fahrenheit to Celsius by selecting the desired U.S./Metric option from the customer programmable features. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the temperature display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. When the ignition switch is turned to the Off position, the last displayed temperature reading stays in the electronic control modules (CMTC, EVIC) memory. When the ignition switch is turned to the On position again, the electronic module will display the memory temperature for one minute; then update the display to the current average temperature reading within five minutes. The temperature function is supported by an ambient temperature sensor. The sensor is mounted near the front and center of the vehicle, and is hard wired to the Powertrain Control Module (PCM). The PCM sends temperature status messages to the module over the Programmable Communication Interface (PCI) data bus circuit. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 8320 Driver/Vehicle Information Display: Description and Operation Electronic Vehicle Information Center Description The Electronic Vehicle Information Center (EVIC) is located in the overhead console. The EVIC features a large Vacuum Fluorescent Display (VFD) screen for displaying information, and back-lit push button switches labeled C/T (compass/thermometer), RESET, STEP, and MENU. The EVIC module contains a central processing unit and interfaces with other electronic modules in the vehicle over the Programmable Communications Interface (PCI) data bus circuit. The EVIC "Menu" push button provides the vehicle operator with a user interface, which allows the selection of several optional customer programmable electronic features to suit individual preferences. If the vehicle is equipped with the optional universal transmitter transceiver, the EVIC will also display messages and an icon indicating when the universal transmitter transceiver is being trained, which of the three transmitter buttons is transmitting, and when the transceiver is cleared. Data input for all EVIC functions, including VFD dimming level, is received through the PCI data bus circuit. The EVIC module uses its internal programming and all of its data inputs to calculate and display the requested data. If the data displayed is incorrect, perform the SELF - DIAGNOSTIC TEST. If these tests prove inconclusive, the use of a DRBIII(R) scan tool and the proper diagnostic procedures information are recommended for further testing of the EVIC module and the PCI data bus circuit. The EVIC module cannot be repaired, and is available for service only as a unit. This unit includes the plastic module and display lens. If any of these components is faulty or damaged, the complete EVIC module must be replaced. The Electronic Vehicle Information Center (EVIC) uses both non-switched and ignition switched sources of battery current so that some of its features remain operational at any time, while others may only operate with the ignition switch in the On position. When the ignition switch is turned to the On position, the EVIC module Vacuum Fluorescent Display (VFD) will return to the last function being displayed before the ignition was turned to the Off position. The compass/thermometer display is the normal EVIC display. With the ignition switch in the On position, momentarily depressing and releasing the C/T (compass/thermometer) push button switch will cause the EVIC to return to the compass/thermometer/trip computer display mode from any other mode. While in the compass/thermometer/trip computer display mode, momentarily depressing and releasing the Step push button will step through the available trip computer display options. The EVIC trip computer features several functions that can be reset. The functions that can be reset are: - Average fuel economy - Trip odometer - Elapsed time With the ignition switch in the On position and with one of the functions of the trip computer that can be reset currently displayed, depressing the Reset push button twice within four seconds will perform a global reset, and all of the trip computer information that can be reset will be reset to zero. With the ignition switch in the On position and the function that is to be reset currently displayed, momentarily depressing and holding the Reset push button for one second will perform a local reset, and only the value of the displayed function will be reset to zero. A global or local reset will only occur if the function currently displayed is a function that can be reset. The distance to service function can also be reset using the local reset method, but it will reset back to the Service Interval distance that is set in the EVIC programmable features mode. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 8321 Driver/Vehicle Information Display: Description and Operation Electronic Vehicle Information Center Operation COMPASS/TEMPERATURE MODULE, COMPASS/MINI-TRIP COMPUTER or ELECTRONIC VEHICLE INFORMATION CENTER The Compass/Temperature Module (CT), Compass/Mini-Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) is located in the overhead console. The CT provides the vehicle operator with only outdoor temperature and the compass heading. The CMTC or EVIC supplements the standard vehicle instrumentation. The CMTC and EVIC use a vacuum fluorescent (VF) display to supply the vehicle operator with a compass heading, outdoor temperature, average fuel economy, distance to empty, trip odometer, elapsed ignition on time, distance to service, warning messages, and service messages. The difference between a CMTC and an EVIC is that only the EVIC provides additional memory, feature programming, and warning messages. The EVIC is capable of displaying warning messages and memory system messages when the vehicle is equipped with memory systems. The EVIC also provides the interface to enable and disable vehicle programmable features when the vehicle is equipped with certain features. If equipped, the EVIC is also available with an integrated Universal Garage Door Opener (UGDO) known as HomeLink(R). The EVIC may also be equipped with up to 4 power door switches: ON/ OFF, Left Sliding Door, Right Sliding Door, and Liftgate. The CT function buttons are labeled C/T and US/M. The CMTC function buttons are labeled US/M, C/T, RESET, and STEP. The EVIC function buttons are labeled C/T, RESET, STEP, and MENU. The three UGDO buttons are labeled with dots to indicate the channel number. The BCM supplies most of the information displayed by the CMTC/EVIC. Display information, except for the internal compass function, is received over the PCI bus. The FCM supplies the ambient temperature sensor information via the PCI bus. The CMTC/EVIC sends and receives data over the PCI bus, communicating with the BCM, PCM, FCM, and the Instrument Cluster. Tire Pressure Monitoring System information is received from the SKREEM via PCI bus information. The tire pressure sensors are mounted to the vehicle wheels. For complete information, refer to the Tire Pressure Monitoring System. VEHICLE INFORMATION DISPLAY The CMTC/EVIC provides the following functions: - Compass direction - Outside temperature - Elapsed ignition on time - Distance to empty - Average fuel economy - Trip odometer - Distance to service The EVIC will also display the following driver alert messages: - TURN SIGNAL ON (with vehicle graphic) - PERFORM SERVICE - DOOR OPEN (individual or multiple doors, with graphic) - LOW TIRE PRESSURE (when equipped) - ADJUSTABLE PEDAL DISABLED CRUISE ENGAGED (when equipped) - ADJUSTABLE PEDAL DISABLED VEHICLE IN REVERSE (when equipped) An audible chime or chimes will accompany any displayed warning messages. Chime requests with an OPEN message are dependent upon vehicle speed. The CT/CMTC/EVIC will not display information for any of the screens for which it did not receive the proper PCI bus data. Refer to the symptom list in the Overhead Console section for problems related to the CT/CMTC/EVIC. The CMTC/EVIC receives the following messages from the Body Control Module (BCM): - Verification of US/Metric status - VF display dimming brightness and exterior lamp status - Elapsed Ignition On Time data - Average Fuel Economy - Distance to Empty - Distance to service - Driver warning messages The CT/CMTC/EVIC receives the following messages from the Front Control Module (FCM): - Outside Temperature The CMTC/EVIC receives the following messages from the Powertrain Control Module (PCM): Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 8322 - Trip Odometer data - Vehicle Speed The EVIC receives the following messages from the Adjustable Pedal System Module (APS): - APS status warnings The CT/CMTC/EVIC receives the following messages from the Sentry Key Remote Electronic Entry Module (SKREEM): - Tire Pressure information The CMTC/EVIC transmits the following messages to the BCM: - Status Request: Beep, Reset, US/M Toggle - Current Display STEP BUTTON The STEP Button can be used in one of the following three ways: 1. To sequentially select one of seven displays or blank display in the following order: - Average Fuel Economy - Distance to Empty - Trip Odometer - Time Elapsed - Distance to Service Message - Off (Blank) 2. To set the magnetic variance zone when VARIANCE = X (X = 1 - 15) is indicated in the VF Display. 3. To select the displayed programmable feature setting. (When equipped.) MENU BUTTON (EVIC only) For complete information of the programmable features and memory messages. Use the MENU button to sequentially step the EVIC through the programmable features. MENU BUTTON (EVIC only) For complete information of the programmable features and memory messages.Use the MENU button to sequentially step the EVIC through the programmable features. RESET BUTTON The RESET Button has two different functions: 1. To clear the trip functions that may be reset 2. To enter and exit the diagnostic mode Pressing the RESET button once will clear the trip function that is currently being displayed (except Distance to Service) and the CMTC/EVIC will send a PCI bus beep request to the BCM. If the RESET button is pressed again within 3 seconds, the CMTC/EVIC will reset ALL of the trip functions and an additional beep request is sent to the BCM. The trip functions that may be reset are: - Average Fuel Economy - Trip Odometer - Elapsed Time A reset will only occur if one of the trip functions that may be reset is currently being displayed. Pressing the RESET button for more than three (3) seconds resets the Distance to Service function while the Distance to Service message is being displayed. The CMTC/EVIC module will send a beep request to the BCM. Simultaneously pressing the RESET button and the STEP button while turning the ignition from Off to On will enter the CMTC/EVIC into the self-diagnostic mode. COMPASS/TEMPERATURE (C/T) BUTTON Actuating the Compass/Temperature Button (C/T) will cause the CMTC/EVIC to display the compass and temperature information. This function will operate from another traveler display or from the programmable feature mode. TRAVELER DISPLAY FUNCTIONS Using the STEP button will change the CMTC/ EVIC between modes of operation and display the appropriate information according to data received from the PCI Bus. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 8323 COMPASS/TEMPERATURE The CMTC/EVIC simultaneously displays the compass reading and the outside temperature. Outside temperature information is received via the PCI bus from the FCM. The CMTC/EVIC module internally senses and calculates the compass direction. COMPASS OPERATION - ALL Upon ignition on, if the calibration information stored in the CMTC memory is within the normal range, the CMTC will perform in slow Auto-Cal mode. In slow Auto-Cal mode, the CMTC continuously compensates for the slowly changing magnetic field of the vehicle. The compass module detects changes in the vehicle magnetism and makes appropriate internal corrections to ensure proper displayed direction. However, if the calibration information stored in the CMTC memory is not within the normal range at ignition on, the CMTC will enter fast Auto-Cal. CAL is displayed along with the temperature. Auto activation of the fast Auto-Cal mode will also occur when the CMTC is subjected to high magnetic field strength levels, which cause all compass readings to be erroneous for a continuous period of five (5) minutes. During fast Auto-Cal, CAL will be displayed along with the temperature. Fast Auto-Cal can also be performed manually, by pressing and holding the RESET button for 10 seconds during the Compass/Temperature display mode. SETTING MAGNETIC ZONE VARIANCE Variance is the difference between magnetic North and geographic North. For proper compass function, the correct variance zone must be set. Refer to the Zone Variance map for the correct zone. Follow these steps to check or change the variance zone: CMTC/EVIC: - The ignition switch must be in the On position and the CMTC/EVIC display must not be blank. - If the compass/temperature data is not currently being displayed, momentarily press and release the C/T button to display compass/temp information. - Press and hold the RESET button (approximately 5 seconds) until VARIANCE = XX is displayed. The CMTC/EVIC will display the variance zone stored in memory and the word VARIANCE. - Use the RESET button to select the proper variance zone number, 1 through 15. - After selecting the proper zone number, momentarily press and release the RESET button. The variance zone is then stored in the memory and the CMTC/EVIC returns to normal operation. CT: - The ignition switch must be in the On position and the C/T display must not be blank. Press and hold the C/T and US/M buttons (approximately 5 seconds) until VARIANCE = XX is displayed. The C/T will display the variance zone stored in memory and the word VARIANCE. - Use the US/M button to select the proper variance zone number, 1 through 15. - After selecting the proper zone number, momentarily press and release the C/T button. The variance zone is then stored in the memory and the C/T returns to normal operation. COMPASS CALIBRATION The compass module has 2 types of auto calibration; slow-cal and fast-cal. Slow-cal ensures that during normal vehicle operation th0e compass performs auto-calibration functions to keep the compass sensors in their proper operating range. Whenever the ignition is On and the CT/CMTC/ EVIC receives PCI bus data indicating that engine RPM is greater than zero, auto-calibration is performed continuously. If the calibration information stored in the compass module memory is not within the normal range after a power-up cycle, the compass will display CAL. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 8324 The CT/CMTC/EVIC will enter into the fast-cal mode until calibration is complete. To enter the compass into Manual Calibration mode, perform the following steps: - Drive the vehicle to an area away from any large metal objects or overhead power lines. - Ensure that the proper variance zone is selected. See "Setting Magnetic Zone Variance". - The ignition switch must be in the On position and the CMTC/EVIC display must not be blank. - Press the C/T button to view the Compass/ Temperature display. - Press and hold the RESET button (approximately 10 seconds) until CAL is displayed, then release the button. - Drive slowly, less than 5 MPH (8 KPH) in at least 1 complete 360-degree circle. - CAL will remain illuminated to alert the driver that the compass is in the calibration mode. - After calibration is complete, CAL will turn off. NOTE: For C/T Manual Calibration, perform the same procedure as above, but press and hold the C/T and US/M buttons until CAL is displayed. If the compass appears blank, unable to be calibrated, or the compass displays false indications,the vehicle must be demagnetized. SELF-CHECK DIAGNOSTICS The CT/CMTC/EVIC is capable of performing a diagnostic self check on its internal functions. Diagnostics may be performed using a DRBIII(R) or by using the following procedure: 1. For CMTC/EVIC: With the ignition switch in the OFF position, depress and hold the RESET and the STEP buttons. For CT: With the ignition switch in the OFF position, depress and hold the C/T and the US/M buttons. 2. Turn the ignition switch to the ON position. 3. Continue to hold both buttons until the software versions are displayed, then release the buttons. 4. All of the VFD segments will illuminate for 2-4 seconds. Check for segments that do not illuminate or illuminate all the time. 5. When the self-check is complete the EVIC will display one of the following messages: - PASS SELF TEST - FAILED SELF TEST - NOT RECEIVING J1850 MESSAGE When the self-check is complete the CT/CMTC will display one of the following messages: - PASS - FAIL - BUS 1. To exit the self-check mode: For the CMTC/EVIC: Depress the STEP or RESET button, or cycle the ignition switch and the CMTC/EVIC will return to normal operation. For the C/T: Depress the C/T or US/M button, or cycle the ignition switch and the CT will return to normal operation. If a Communication fault is displayed, refer to the symptom list. If a FAIL or FAILED is displayed, the CT/CMTC/EVIC must be replaced. AMBIENT TEMPERATURE SENSOR The ambient air temperature is monitored by the FCM and displayed by the CT/CMTC/EVIC. The FCM receives a hardwire input from the ambient temperature sensor (ATS). The ATS is a variable resistor that operates on a 5-volt reference signal circuit hardwired from the FCM. The resistance in the ATS changes as the outside temperature rises or falls. The FCM senses the change in reference voltage through the ATS resistor. Based on the resistance of the ATS, the FCM is programmed to correspond to a specific temperature. The FCM stores and filters the ambient temperature data and transmits this data to the CMTC/EVIC via the PCI Bus. The ATS cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. AMBIENT TEMPERATURE SENSOR FAULT CODES The outside temperature function is supported by the ambient temperature sensor (ATS), a signal and ground circuit hardwired to the FCM, and the CMTC/EVIC display. If the ATS sense circuit is shorted to ground, the temp display will be 54° C (130° F) to indicate SHORT circuit condition. If the ATS sense circuit is open, the temp display will be -40° C (-40° F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the CMTC/EVIC VFD can be tested. The ATS is supported by the FCM. Ambient Temperature Sensor DTC's will be recorded in the FCM. The ATS can be diagnosed using the following Sensor Test. Test the ATS circuits using the diagnostics in the Body Diagnostic Procedures Manual. If the CMTC/EVIC passes the self-test, and the ATS, the circuits, and PCI bus communications are confirmed to be OK, but the CMTC/EVIC temperature display is inoperative or incorrect, replace the FCM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 8325 AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: 0° C (32° F) Sensor Resistance = 29.33 - 35.99 Kilohms - 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kilohms - 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kilohms - 25° C (77° F) Sensor Resistance = 9.12 - 10.86 Kilohms - 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kilohms - 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance values are not OK, replace the Sensor. HOMELINK(R) UNIVERSAL TRANSMITTER If equipped, HomeLink(R) Universal Transmitter is integrated into the overhead console. For added security it will operate home security systems that use coded signals known generically as Rolling Codes. The overhead console display provides visual feedback to the driver, indicating which HomeLink(R) transmitter channel button is being pressed. The HomeLink(R) can learn and store up to three separate transmitter radio frequency codes to operate garage door openers, security gates, and security lighting. The HomeLink(R) buttons are marked with one, two, or three dots. For complete information. TIRE PRESSURE MONITORING SYSTEM (TPMS) If equipped with the Tire Pressure Monitoring System (TPMS), each of the vehicles four wheels will have a valve stem with a pressure sensor and radio transmitter built in. Signals from the tire pressure Sensor/Transmitter are received and interpreted by the Sentry Key Remote Entry Module (SKREEM). Using the DRBIII(R), go to ANTI-THEFT for the SKREEM data. A Sensor/Transmitter in a mounted wheel will broadcast an RF frequency indicating its pressure once per minute when the vehicle is in drive mode. To activate the Sensor/Transmitter operation, the required SKREEM speed is 13 mph (20 km/h). Each Sensor/Transmitters broadcast is uniquely coded so that the SKREEM can monitor the states of each Sensor/Transmitter on the vehicle. The SKREEM TPMS does not use a magnet to relearn, it automatically learns while driving after a SKREEM or a Sensor/Transmitter has been replaced. TRAINING THE SKREEM If a Sensor/Transmitter is replaced, the vehicle has to be parked for at least 15 minutes for the system to be ready to learn the new Sensor/Transmitter ID code. The vehicle then must be driven for a minimum of five minutes with a minimum continuous speed above 13 mph (20 km/h). The system will learn the new Sensor/Transmitter and clear the DTC's automatically. The Sensor/ Transmitters are programmed at the assembly plant in this clockwise orientation: Sensor/Transmitter 1 = Left Front Sensor/Transmitter 2 = Right Front Sensor/Transmitter 3 = Right Rear Sensor/Transmitter 4 = Left Rear NOTE: 1. If one or all Sensor/Transmitters cannot be trained, check for and avoid RF interference. 2. If one Sensor/Transmitter still cannot be trained, replace it and retry. 3. If all Sensor/Transmitters still fail to train, replace the SKREEM. PRESSURE THRESHOLDS The SKREEM will monitor the tire pressure signals from the Sensor/Transmitters and determine if any tire has gone below the low-pressure or above the high-pressure thresholds. Refer to the tables below: Low Tire Pressure Thresholds Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 8326 High Tire Pressure Thresholds *Tolerance ±6.9 kPa (1 PSI) ACTIVE FAULT AND SYSTEM ALERTS An active fault will be triggered when a system failure has been detected. When this occurs, the Instrument Cluster will illuminate the TPMS indicator and the SKREEM will store the fault code. An alert will be triggered when a tire pressure has gone below or above the set threshold pressure. When this occurs, the Instrument Cluster will flash the TPMS indicator. The SKREEM will request a secondary message to be displayed on the EVIC (if equipped). Only when a tire pressure has gone below the set threshold pressure will the SKREEM request the TPMS indicator to flash and display the EVIC message (if equipped). When a high pressure alert occurs, only the EVIC message will be displayed. This action will be displayed as long as the alert condition is active. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 8327 Driver/Vehicle Information Display: Description and Operation Universal Transmitter A Universal Transmitter transceiver is available on some vehicles. The universal transmitter transceiver is integral to the Electronic Vehicle Information Center (EVIC) and the Compass Mini-Trip Computer (CMTC) modules, which are located in the overhead console. The only visible component of the universal transmitter are the three transmitter push buttons centered between the modules push buttons located just rearward of the display screen in the overhead console. The three universal transmitter push buttons are identified with one, two or three light indicators so that they can be easily identified. Each of the three universal transmitter push buttons controls an independent radio transmitter channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 286 to 399 MegaHertz (MHz) frequency range for remote operation. The universal transmitter is capable of operating systems using either rolling code or non-rolling code technology. The electronics module displays messages and a small house-shaped icon with one, two or three dots corresponding to the three transmitter buttons to indicate the status of the universal transmitter. The EVIC messages are: - Cleared Channels - Indicates that all of the transmitter codes stored in the universal transmitter have been successfully cleared. - Training - Indicates that the universal transmitter is in its transmitter learning mode. - Trained - Indicates that the universal transmitter has successfully acquired a new transmitter code. - Transmit - Indicates that a trained universal transmitter button has been depressed and that the universal transmitter is transmitting. The universal transmitter cannot be repaired, and is available for service only as a unit with the EVIC or CMTC modules. If any of these components is faulty or damaged, the complete EVIC or CMTC module must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Component Tests and General Diagnostics Driver/Vehicle Information Display: Component Tests and General Diagnostics Electronic Vehicle Information Center Electronic Vehicle Information Center (EVIC) data is obtained from the Body Control Module (BCM) on the Programmable Communications Interface (PCI) Data Bus circuit. The EVIC will display dashes (- -) for any of the screens it did not receive the bus messages. The label corresponding to the missing information will be lit. If no EVIC data is displayed, check the PCI Data Bus circuit communications and the BCM. If the dimming level is improper check the PCI Data Bus circuit. The use of a DRBIII(R) scan tool and the proper diagnostic procedures information are recommended for further testing of the EVIC module and the PCI data bus circuit. Perform the SELF-DIAGNOSTIC TEST before replacing the EVIC module. Overhead Console Any diagnosis of the overhead console should begin with the use of the DRB III(R) diagnostic tool. For information on the use of the DRB III(R), refer to the appropriate Diagnostic Procedures information. If the problem with the overhead console is an inaccurate or dashed (- -) display, refer to SELF-DIAGNOSTIC TEST. If the problem with the overhead console is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a DRB III(R) scan tool and the proper diagnostic procedures information to test for the correct dimming message inputs being received from the Body Control Module (BCM) or Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus circuit. If the problem is a no-display condition, use the following procedures. Inspect the related wiring harness connectors for broken, bent, pushed out, or corroded terminals. Refer to the appropriate wiring information. 1. Check the fused B(+) fuse in the integrated power module. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse in the integrated power module. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the fused B(+) fuse in the integrated power module as required. 3. Check the fused ignition switch output (run/ start) fuse in the integrated power module. If OK, go to Step 4. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 4. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run/start) fuse in the integrated power module. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run/start) circuit to the ignition switch as required. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the overhead console. Check for continuity between the ground circuit cavity of the roof wire harness connector for the electronics module and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the roof wire harness connector for the electronics module. If OK, go to Step 7. If not OK, repair the open fused B(+) circuit to the fused B(+) fuse in the integrated power module as required. 7. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run/start) circuit cavity of the roof wire harness connector for the electronics module. If OK, refer to SELF-DIAGNOSTIC TEST. If not OK, repair the open fused ignition switch output (run/start) circuit to the fuse in the integrated power module as required. SELF-DIAGNOSTIC TEST A self-diagnostic test is used to determine that the electronics module is operating properly, and that all the PCI data bus messages are being received for initial operation. Initiate the self-diagnostic test as follows: 1. With the ignition switch in the Off position, on Electronic Vehicle Information Center (EVIC) and Compass Mini-Trip Computer (CMTC) equipped vehicles simultaneously depress and hold the STEP and the RESET buttons. On Compass Temperature Module (CT) equipped vehicles depress the C/T and the US/M push buttons. 2. Turn the ignition switch to the On position. 3. Following completion of these tests, the electronics module will display one of the following messages: a. Pass Self Test (EVIC only), PASS (CT, CMTC) - The electronics module is working properly. b. Failed Self Test (EVIC only), FAIL (CT, CMTC) - The electronics module has an internal failure. The electronics module is faulty and must be replaced. NOTE: - If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. - If the compass reading display is blank and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Universal Transmitter Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 8330 Radio Frequency Detector If both the Universal Transmitter and the Electronic Vehicle Information Center (EVIC) are inoperative. If the Universal Transmitter is inoperative, but the EVIC is operating normally, retrain the Transmitter with a known good transmitter. If the unit is still inoperative, test the universal transmitter with the Radio Frequency Detector special tool as described below: 1. Turn the Radio Frequency (RF) Detector ON. A "chirp" will sound and the green power LED will light. If the green LED does not light, replace the battery. 2. Hold the RF detector within one inch of the TRAINED universal transmitter and press any of the transmitters buttons. 3. The red signal detection LEDs will light and the tool will beep if a radio signal is detected. Repeat this test three times. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 8331 Driver/Vehicle Information Display: Programming and Relearning Programming Transmiter Codes 1. Turn off the engine. 2. Erase the codes by pressing the two outside buttons. Release the buttons when the display confirms the operation (about 20 seconds). 3. Choose one of the three buttons to train. Place the hand-held transmitter within one inch of the universal transmitter and push the buttons on both transmitters. 4. Release both buttons. Your universal transmitter is now "trained". To train the other buttons, repeat Step 3 and Step 4. Be sure to keep your handheld transmitter in case you need to retrain the universal transmitter. Erasing Transmitter Codes To erase the universal transmitter codes, simply hold down the two outside buttons until the display confirms the operation. NOTE: Individual channels cannot be erased. Erasing the transmitter codes will erase ALL programmed codes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Electronic Vehicle Information Center Programming Driver/Vehicle Information Display: Service and Repair Electronic Vehicle Information Center Programming Some vehicles are equipped with a Electronic Vehicle Information Center (EVIC) equipped overhead console. The Electronic Vehicle Information Center (EVIC) provides the vehicle operator with a user interface, which allows the selection of several optional customer programmable electronic features to suit individual preferences. The EVIC must be placed into its programming mode in order to view or change the programmable features. To enter the EVIC programming mode and to view or change the selected programmable features options, proceed as follows: 1. Turn the ignition switch to the On position. 2. Depress and release the Menu push button. The first item in the programmable features menu list will appear in the EVIC display. 3. Momentarily depress and release the Menu push button to step through the programmable features list. Each programmable feature and its currently selected option will appear on the EVIC display in the sequence shown in the Programmable Features list that follows. 4. Momentarily depress and release the Step push button to step through the available options for the programmable feature being displayed. 5. The option that last appears in the display with a programmable feature before exiting the programming mode, becomes the newly selected programmable feature option. 6. The EVIC exits the programming mode and returns to its normal operating mode when the C/T push button is depressed or when the end of the programmable features menu list is reached, whichever occurs first. PROGRAMMABLE FEATURES NOTE: Tire pressure monitoring (TPM) system information is not covered. Refer to the tires/wheels of this manual for detailed tire pressure monitoring system information. - LANGUAGE? - The options include English, Francaise, Deutsch, Italiana, or Espanol. The default is English. All EVIC display nomenclature, including the trip computer functions, warning messages and the programmable features appear in the selected language. - DISPLAY U.S. OR METRIC? - The options include U.S. and M. The default is U.S. This feature toggles the trip computer temperature, fuel economy and odometer display readings between U.S. and metric units of measure. It also changes the odometer display in the instrument cluster. - SERVICE INTV. = - The options include from 3200 to 12000 kilometers in 800 kilometer increments (2000 to 7500 miles in 500 mile increments). The default is 12000 kilometers (7500 miles). The selected distance becomes the interval at which the Perform Service warning message will be displayed by the EVIC. If a new distance is selected, a second programmable feature appears, RESET SERVICE DISTANCE? - The options include No and Yes. The default is Yes. When Yes is selected, the accumulated distance since the last previous Perform Service warning message will be reset to zero because the service interval has been changed. When No is selected, the distance until the next Perform Service warning message is reduced by the accumulated distance since the last previous message. - USE FACTORY SETTINGS? - The options include Yes and No. The default is Yes. When yes is selected all the programmable features will return to there defaults and the rest of the programmable features will not be displayed. If No is selected the rest of the programmable features will be displayed at there current chosen values. This feature will automatically return to the Yes default under two conditions. First, if no programmable features are changed from there defaults. Second, if all the programmable features equal there defaults. - AUTO DOOR LOCKS? - The options include Yes and No. The default is Yes. When Yes is selected, all doors and the liftgate lock automatically when vehicle speed reaches 25 kilometers-per-hour (15 miles-per-hour). If YES is selected, a second programmable feature appears, AUTO UNLOCK ON EXIT? - The options again include Yes and No. The default is No. When Yes is selected, following each Auto Door Lock event all doors and the liftgate will automatically unlock when the driver door is opened, if the vehicle is stopped and the transmission gear selector is in Park or Neutral. The Auto Door Unlock event will only occur once following each Auto Door Lock event. - REMOTE UNLOCK - The options include Driver Door 1st and All Doors. The default is Driver Door 1st. When Diver Door 1st is selected, only the driver door unlocks when the Unlock button of the Remote Keyless Entry (RKE) transmitter is depressed once. The Unlock button of the RKE transmitter must be depressed twice to unlock all doors. When All Doors is selected, all doors unlock when the Unlock button of the RKE transmitter is depressed once. - REMOTE LINKED TO MEMORY? - This programmable feature only applies to vehicles equipped with the optional memory / heated system. The options include Yes and No. The default is No. When Yes is selected, the memory system will recall the Driver 1 or Driver 2 memory settings assigned to the RKE transmitter being used to unlock the vehicle. When No is selected, the memory system will only recall memory settings when the Driver 1 or Driver 2 push buttons of the memory switch on the driver side front door trim panel are depressed. - SOUND HORN ON LOCK? - The options include Yes and No. The default is No. When Yes is selected, a short horn chirp will provide an audible confirmation when the RKE receiver recognizes a valid Lock signal from an RKE transmitter. When No is selected, no horn chirp will occur with the RKE Lock event. This feature may be selected independent of the FLASH LIGHTS WITH LOCKS? programmable feature. - FLASH LIGHTS WITH LOCKS? - The options include Yes and No. The default is Yes. When Yes is selected, a single flash of the hazard warning lamps will provide an optical confirmation when the RKE receiver recognizes a valid Lock signal from an RKE transmitter, and two flashes of the same lamps will occur when the RKE receiver recognizes a valid Unlock signal from an RKE transmitter. When No is selected, no lamp flash will occur with the RKE Lock or Unlock event. This feature may be selected independent of the SOUND HORN ON LOCK? programmable feature. - HEADLAMP DELAY = - The options include Off, 30 Sec, 60 Sec, and 90 Sec. The default is 90 Sec. When a time interval is selected, the headlamps will remain on for that length of time when the headlamps are turned off after the ignition is turned off, or if the Auto mode is selected on vehicles with the Auto Headlamps option. When Off is selected, the headlamp delay feature is disabled. - HEADLAMPS ON WITH WIPERS? - This programmable feature only applies to vehicles equipped with the optional Auto Headlamps. The options include Yes and No. The default is No. When Yes is selected, the headlamps will turn on automatically when the windshield wipers are turned on. The headlamps will turn off when the wipers are turned off, as long as the headlamp switch is in the Auto or Off positions. When No is selected, the headlamps will only turn on if manually selected or if the Auto mode is selected and the outside ambient light levels dictate that they should be on. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Electronic Vehicle Information Center Programming > Page 8334 - POWER ACCESSORY DELAY? - The options include Yes and No. The default is Yes. When No is selected, the accessory powered components will turn off automatically when the ignition key is turned off. When Yes is selected, the accessory powered components will remain on for 45 seconds when the ignition key is turned off. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Electronic Vehicle Information Center Programming > Page 8335 Driver/Vehicle Information Display: Service and Repair Electronic Vehicle Info Center REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove overhead console. 3. Remove the ten screws holding the Electronic Vehicle Information Center (EVIC) module in the overhead console. 4. Remove EVIC module from console assembly. NOTE: If the EVIC module is being replaced, the tire pressure monitoring system (if equipped) must be retrained. INSTALLATION 1. Position the Electronic Vehicle Information Center (EVIC) module in the overhead console. 2. Install the ten screws holding the EVIC module in the overhead console. 3. Install the overhead console. 4. Connect the battery negative cable. NOTE: If the EVIC module is being replaced, the tire pressure monitoring system (if equipped) must be retrained. - If a new EVIC module has been installed, the compass will have to be calibrated and the variance set. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Description and Operation Television / Monitor: Description and Operation VIDEO SCREEN The video screen (if equipped) is mounted on the headliner behind the driver and front passenger seat. Pressing the release button will allow the screen to be opened. Operating instructions for the factory installed video screen can be found provided with this vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Description and Operation > Page 8340 Television / Monitor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative battery cable. 2. Remove the lens bezel. Video Screen 3. Remove the rear console screws. 4. Remove the rear A/C trim bezel. 5. Disconnect A/C wire harness connector. 6. Remove remaining mounting screws. 7. Disconnect wire harness connectors. INSTALLATION 1. Connect wire harness connectors. 2. Install front mounting screws. 3. Install the rear A/C trim bezel. 4. Install the rear mounting screws. 5. Install the lens bezel. 6. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams DVD Player: Diagrams C204 (DVD) C204 (DVD) C206 (DVD/Hands Free) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams > Page 8344 DVD Screen DVD/CD Changer C1 DVD/CD Changer C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams > Page 8345 DVD Player: Description and Operation The DVD player (if equipped) is located in the instrument panel below the radio. The DVD player can hold one DVD at a time. Three RCA jacks on the front of the unit allow the use of MP3 players, video game systems or camcorders. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Diagrams > Page 8346 DVD Player: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. DVD Player 2. Remove screws holding DVD player. 3. Disconnect the wire connector from the back of the DVD player. 4. Remove the DVD player from the vehicle. INSTALLATION 1. Connect the wire harness connector to the DVD player. 2. Insert the DVD player into the instrument panel. 3. Install mounting screws. 4. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8351 Memory Positioning Module: Description and Operation Vehicles equipped with the memory seat/mirror option, utilize a memory module located under the drivers front seat. This module is basically wired in-line between the power seat switch and the power seat track/adjuster motors, or in-line between the power mirror switch and the power side view mirror(s) motor(s). The Memory Seat/Mirror Module (MSMM) contains a central processing unit that communicates with other modules on the Programmable Communications Interface (PCI) data bus network. The MSMM receives hard wired inputs from the driver power seat switch and the potentiometers on each of the driver side power seat track motors, or from the power mirror switch and the potentiometers on the side view mirror. The MSMM receives messages over the PCI data bus from the Body Control Module (BCM) (memory switch status), the Powertrain Control Module (PCM) (vehicle speed status). The MSMM will prevent the seat memory recall function from being initiated if the driver side seat belt is buckled, if the transmission gear selector lever is not in the Park or Neutral positions, or if the vehicle is moving. For diagnosis of the MSMM or the PCI data bus, a DRB III(R) scan tool and the proper Diagnostic Procedures Information are recommended. The MSMM cannot be repaired and, if faulty or damaged, it must be replaced. When memory system operation is requested (depressing of the memory switch), a resistor multiplexed signal is sent from the memory switch to the Body Control Module (BCM). The BCM will then send the appropriate signals out to the Memory Seat/ Mirror Module (MSMM), the MSMM then applies the voltage supply to the power seat track or side-view mirror if the proper requirements are met. The vehicle speed must equal zero and the transmission must be in park or neutral in order for the memory system to function. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8352 Memory Positioning Module: Testing and Inspection Any diagnosis of the Memory Seat/Mirror system should begin with the use of the DRB III(R) diagnostic tool. Inspect the related wiring harness connectors for broken, bent, pushed out, or corroded terminals. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 8353 Memory Positioning Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side front bucket seat retaining nuts from under the vehicle. 3. Lift the drivers seat up and out of the mounting holes in the floor pan and lay the seat rearward to access the module located under the seat. 4. Disconnect the memory seat/mirror module electrical connectors. Depress the retaining tab and pull straight apart. 5. Remove the module retaining bolts and remove the module from the bracket. INSTALLATION 1. Position and install the module retaining bolts. 2. Connect the memory seat/mirror module electrical connectors. 3. Position the drivers seat in the mounting holes in the floor pan. 4. Install the driver side front bucket seat retaining nuts from under the vehicle. 5. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Driver Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 8357 Memory Set Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 8358 Seat Memory Switch: Description and Operation Memory Switch Location Vehicles equipped with the memory system have a memory switch mounted to the driver side front door trim panel. This switch is used to set and recall all of the memory system settings for up to two drivers. The memory switch is a resistor multiplexed unit that is hard wired to the Body Control Module (BCM). The BCM sends out the memory system set and recall requests to the other electronic modules over the Programmable Communications Interface (PCI) data bus. The memory switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The memory switch has three momentary switch buttons labeled Set, 1 and 2. When the memory set switch is depressed, a resistance value is sent to the Body Control Module (BCM) via hard wired connections. When the memory system is in "set" mode a chime will be generated by the BCM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 8359 Seat Memory Switch: Testing and Inspection MEMORY SWITCH Memory Switch Test Table 1. Remove the memory switch from the drivers door panel. 2. Using an ohmmeter, check the continuity of the memory select switch MUX circuit between the C2 wire harness connector for the Body Control Module (BCM) and the wire harness connector for the memory switch. There should be continuity. If OK, go to Step 3. If not OK, repair the open or shorted MUX circuit as required. 3. Using an ohmmeter, check the continuity of the memory select switch return circuit between the C2 wire harness connector for the BCM and the wire harness connector for the memory switch. There should be continuity. If OK, go to Step 4. If not OK, repair the open or shorted return circuit as required. 4. Using an ohmmeter, test the resistances of the memory switch. If OK, refer to Body and Frame / Seats / Testing and Inspection. If not OK, replace the memory switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 8360 Seat Memory Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door trim panel switch bezel from the driver side front door. Using a thin flat-bladed pry tool, gently pry the switch bezel away from the drivers door trim panel. 3. Disconnect the memory switch wire harness connector from the memory switch. 4. Remove the two screws that secure the memory switch to the back of the driver side front door trim panel switch bezel. 5. Remove the memory switch. INSTALLATION 1. Position the memory switch and install and tighten the two screws that secure the memory switch to the back of the driver side front door trim panel switch bezel. Tighten the screws to 2.2 Nm (20 in. lbs.). 2. Reconnect the memory switch wire harness connector to the memory switch. 3. Install the trim panel switch bezel onto the driver side front door. 4. Reconnect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Module > Component Information > Locations > Page 8365 Pedal Positioning Module: Diagrams Memory Seat/Mirror/Adjustable Pedals Module C1 Memory Seat/Mirror/Adjustable Pedals Module C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Module > Component Information > Locations > Page 8366 Memory Seat/Mirror/Adjustable Pedals Module C3 Memory Seat/Mirror/Adjustable Pedals Module C4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Diagrams Adjustable Pedals Motor (Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Relay > Component Information > Locations Left Side Engine Compartment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Relay > Component Information > Locations > Page 8373 Adjustable Pedals Relay (Except Export/Except Memory) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Sensor > Component Information > Diagrams Adjustable Pedals Sensor (Memory Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 8380 Adjustable Pedals Switch (Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 8381 Pedal Positioning Switch: Service and Repair ADJUSTABLE PEDALS SWITCH REMOVAL The adjustable pedals switch is located in the steering column lower shroud. Remove the shroud, then remove the switch. INSTALLATION The adjustable pedals switch is located in the steering column lower shroud. Install the switch in the shroud, then install the shroud. Once installed, test for proper operation of the adjustable pedals. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams Amplifier: Diagrams Amplifier C1 (Highline Audio) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 8386 Amplifier C2 (Highline Audio) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 8387 Amplifier: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the right quarter trim panel. 3. Remove the right rear speaker. 4. Disconnect the two electrical harness retainers near the amplifier. Amplifier 5. Remove the mounting fasteners. 6. Disconnect the electrical harness connectors and remove the amplifier through the right rear speaker opening. 7. Remove the bracket from the amplifier. INSTALLATION 1. Install bracket to amplifier 2. Connect the electrical harness connectors, and position amplifier. 3. Install and tighten mounting fasteners. 4. Install the two electrical harness retainers. 5. Install the right rear speaker. 6. Install right quarter trim panel. 7. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams CD Changer: Diagrams CD Changer DVD/CD Changer C1 DVD/CD Changer C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 8392 Radio C2 (CD Changer) Radio C2 (DVD/CD Changer) Radio C2 (Hands Free) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 8393 CD Changer: Description and Operation The 6 Disc In-Dash CD Changer (if equipped) is located in the instrument panel below the radio. The remote changer does not use a cartridge or magazine for the CD's. Up to 6 CD's can be directly loaded into this unit. Due to its compact design, the CD changer can carry out only one operation at a time. For example, you can not load a new disc while playing another at the same time. Each operation happens sequentially. The radio unit provides control over all features of the CD changer with the exception of the CD load and eject functions, which are controlled by buttons located on the front of the CD changer. All features you would expect, such as Disc Up/Down, Track Up/Down, Random and Scan are controlled by the radio, which also displays all relevant CD changer information on the radio display. The CD changer contains a Eject button, six disc buttons, an indicator LED for each of the six disc positions as well as an illuminated disc opening. The individual LED indicates whether a CD is currently loaded in that particular chamber of the CD changer. Pressing the individual button for a particular chamber, then the Eject button will eject a disc currently present in that chamber. If the chamber is currently empty, actuating the individual button will position that chamber to receive and load a new disc in that chamber. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Diagrams > Page 8394 CD Changer: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove screws holding CD changer. 3. Disconnect the wire connector from the back of the CD changer. CD - Changer 4. Remove the CD changer from the vehicle. INSTALLATION 1. Reconnect the wire connector to the CD changer. 2. Insert the CD changer into the instrument panel. NOTE: Use care when inserting CD changer so that cable is not pinched or trapped against instrument panel. 3. Install screws holding CD changer. 4. Reconnect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Technical Service Bulletins > Customer Interest for Radio Receiver: > 08-055-05 > Oct > 05 > Audio System - Satellite Radio Static Radio Receiver: Customer Interest Audio System - Satellite Radio Static NUMBER: 08-055-05 GROUP: Electrical DATE: October 19, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER CONNECTOR PARTS OR PERFORM ANY ACTIONS RELATED TO CS, KJ, LH, PT, RS, WK and XK VEHICLES UNTIL NOVEMBER 28, 2005. SUBJECT: Satellite Radio Intermittent Static OVERVIEW: This bulletin involves replacing the Satellite Digital Audio Receiver (SDAR). MODELS: 2005 (CS) Pacifica 2005 (DR) Ram Truck 2004-2005 (HB) Durango 2005 (JR) Sebring Sedan/Stratus Sedan 2005 (KJ) Liberty 2004 (LH) 300M 2005 (LX) 300/Magnum 2005 (ND) Dakota 2003 - 2005 (PT) Chrysler PT Cruiser 2005 (RS) Town & Country/Caravan 2005 (WK) Grand Cherokee NOTE: This bulletin applies to vehicles equipped with a satellite radio receiver (sales code RSA or RSB) or dealer installed MOPAR satellite radio receiver part numbers 05064002A* and 05064020A*. SYMPTOM/CONDITION: The vehicle operator describes extreme static over the satellite radio audio (only when in the satellite mode) to the point of almost completely covering the intended audio. The static occurs at vehicle start-up, or the first time the radio is put into the satellite mode on a key cycle. The static will last the entire key cycle. This issue is completely intermittent, and in the next key cycle, operation may go back to normal. DIAGNOSIS: Due to the intermittent nature of the condition, demonstration of the issue is difficult. If the vehicle operator description is similar to the Symptom/Condition explained above, perform the Repair Procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Technical Service Bulletins > Customer Interest for Radio Receiver: > 08-055-05 > Oct > 05 > Audio System - Satellite Radio Static > Page 8404 PARTS REQUIRED: REPAIR PROCEDURE: 1. Use the procedures outlined in TechCONNECT 8-Electrical/Audio/Antenna Module/Removal/Receiver-Satellite to remove the SDAR and separate it from it mounting bracket. NOTE: In the near future, the TechCONNECT path to the SDAR procedures will change. Receiver-Satellite will have its own heading under Audio. 2. CS, KJ, LH , PT, RS, WK and XK vehicles go to step 4. DR, HB, JR and ND go step 3. LX vehicles require the SDAR mounting bracket to be modified as follows: a. Place a drop of paint or correction fluid (white out) on the top of each of the (3) SDAR mounting studs of the replacement SDAR. b. Position the SDAR mounting studs against the SDAR mounting bracket so the wiring connectors of the SDAR are facing toward the front of the vehicle when the SDAR/bracket assembly is mounted in the vehicle and the mounting stud opposite the SDAR wiring connectors is 3/16 in. inboard of the crease in the SDAR mounting bracket, (Fig. 1) c. Drill 5/16 in. (8 mm) holes in the SDAR mounting bracket at the three locations marked by the paint. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Technical Service Bulletins > Customer Interest for Radio Receiver: > 08-055-05 > Oct > 05 > Audio System - Satellite Radio Static > Page 8405 3. For DR, HB, JR, LX and ND vehicles, remove the left locating key (when viewed with the SDAR mounting studs facing you) on the tan connector of the SDAR. The key can be shaved off using a utility knife or similar device, (Fig. 2). Continue with step 8. 4. Slide the red lock on the blue connector housing of the antenna harness to its unlock position. 5. Use a small screwdriver to pull up on the tab uncovered by the lock. 6. Slide the housing off the connector terminal. 7. Replace the removed blue connector housing and red lock with the "tan" colored housing, p/n 05189968AA and white lock p/n 05189969AA. 8. Record the Electronic Serial Number (ESN) of the removed and replacement SDAR's, (Fig. 3). 9. Install the appropriate replacement SDAR to the mounting bracket, tighten the fasteners to 5-7 Nm (18-25 in. lbs.). 10. Tape back the original white connector to the antenna harness to prevent rattling. This white connector will NOT be used with the new SDAR. 11. Connect the antenna connector to the tan connector on the new SDAR. Insert the 12-way connector to the module. NOTE: Be sure to route the SDAR wiring so that is has no bends with a radius of less than 1 in. and is free of contact with the mounting bracket, tape, foam or convolute may be used to isolate the wiring if necessary. 12. Install the SDAR/bracket assembly into the vehicle, tighten the fasteners to 5-7 Nm (18-25 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Technical Service Bulletins > Customer Interest for Radio Receiver: > 08-055-05 > Oct > 05 > Audio System - Satellite Radio Static > Page 8406 NOTE: When activating the new SDAR, the vehicle must be in open sky with no obstructions over the antenna. 13. The new SDAR MUST be activated to be able to receive satellite programs. The customer's Sirrus account number or phone number, customer's complete address, and the ESN of the original and new SDAR are required. The ESN is on the SDAR itself, (Fig. 3), or can be retrieved through the radio. With both ESN's, the customer's Sirrus account number or phone number, customer's complete address in hand, call Sirrus at 888-539-7474, (to skip the recordings, press 1 then 3 and 3 again). Explain the transfer that needs to take place when the Sirrus agent answers. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Receiver: > 08-055-05 > Oct > 05 > Audio System - Satellite Radio Static Radio Receiver: All Technical Service Bulletins Audio System - Satellite Radio Static NUMBER: 08-055-05 GROUP: Electrical DATE: October 19, 2005 THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER CONNECTOR PARTS OR PERFORM ANY ACTIONS RELATED TO CS, KJ, LH, PT, RS, WK and XK VEHICLES UNTIL NOVEMBER 28, 2005. SUBJECT: Satellite Radio Intermittent Static OVERVIEW: This bulletin involves replacing the Satellite Digital Audio Receiver (SDAR). MODELS: 2005 (CS) Pacifica 2005 (DR) Ram Truck 2004-2005 (HB) Durango 2005 (JR) Sebring Sedan/Stratus Sedan 2005 (KJ) Liberty 2004 (LH) 300M 2005 (LX) 300/Magnum 2005 (ND) Dakota 2003 - 2005 (PT) Chrysler PT Cruiser 2005 (RS) Town & Country/Caravan 2005 (WK) Grand Cherokee NOTE: This bulletin applies to vehicles equipped with a satellite radio receiver (sales code RSA or RSB) or dealer installed MOPAR satellite radio receiver part numbers 05064002A* and 05064020A*. SYMPTOM/CONDITION: The vehicle operator describes extreme static over the satellite radio audio (only when in the satellite mode) to the point of almost completely covering the intended audio. The static occurs at vehicle start-up, or the first time the radio is put into the satellite mode on a key cycle. The static will last the entire key cycle. This issue is completely intermittent, and in the next key cycle, operation may go back to normal. DIAGNOSIS: Due to the intermittent nature of the condition, demonstration of the issue is difficult. If the vehicle operator description is similar to the Symptom/Condition explained above, perform the Repair Procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Receiver: > 08-055-05 > Oct > 05 > Audio System - Satellite Radio Static > Page 8412 PARTS REQUIRED: REPAIR PROCEDURE: 1. Use the procedures outlined in TechCONNECT 8-Electrical/Audio/Antenna Module/Removal/Receiver-Satellite to remove the SDAR and separate it from it mounting bracket. NOTE: In the near future, the TechCONNECT path to the SDAR procedures will change. Receiver-Satellite will have its own heading under Audio. 2. CS, KJ, LH , PT, RS, WK and XK vehicles go to step 4. DR, HB, JR and ND go step 3. LX vehicles require the SDAR mounting bracket to be modified as follows: a. Place a drop of paint or correction fluid (white out) on the top of each of the (3) SDAR mounting studs of the replacement SDAR. b. Position the SDAR mounting studs against the SDAR mounting bracket so the wiring connectors of the SDAR are facing toward the front of the vehicle when the SDAR/bracket assembly is mounted in the vehicle and the mounting stud opposite the SDAR wiring connectors is 3/16 in. inboard of the crease in the SDAR mounting bracket, (Fig. 1) c. Drill 5/16 in. (8 mm) holes in the SDAR mounting bracket at the three locations marked by the paint. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Receiver: > 08-055-05 > Oct > 05 > Audio System - Satellite Radio Static > Page 8413 3. For DR, HB, JR, LX and ND vehicles, remove the left locating key (when viewed with the SDAR mounting studs facing you) on the tan connector of the SDAR. The key can be shaved off using a utility knife or similar device, (Fig. 2). Continue with step 8. 4. Slide the red lock on the blue connector housing of the antenna harness to its unlock position. 5. Use a small screwdriver to pull up on the tab uncovered by the lock. 6. Slide the housing off the connector terminal. 7. Replace the removed blue connector housing and red lock with the "tan" colored housing, p/n 05189968AA and white lock p/n 05189969AA. 8. Record the Electronic Serial Number (ESN) of the removed and replacement SDAR's, (Fig. 3). 9. Install the appropriate replacement SDAR to the mounting bracket, tighten the fasteners to 5-7 Nm (18-25 in. lbs.). 10. Tape back the original white connector to the antenna harness to prevent rattling. This white connector will NOT be used with the new SDAR. 11. Connect the antenna connector to the tan connector on the new SDAR. Insert the 12-way connector to the module. NOTE: Be sure to route the SDAR wiring so that is has no bends with a radius of less than 1 in. and is free of contact with the mounting bracket, tape, foam or convolute may be used to isolate the wiring if necessary. 12. Install the SDAR/bracket assembly into the vehicle, tighten the fasteners to 5-7 Nm (18-25 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Receiver > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio Receiver: > 08-055-05 > Oct > 05 > Audio System - Satellite Radio Static > Page 8414 NOTE: When activating the new SDAR, the vehicle must be in open sky with no obstructions over the antenna. 13. The new SDAR MUST be activated to be able to receive satellite programs. The customer's Sirrus account number or phone number, customer's complete address, and the ESN of the original and new SDAR are required. The ESN is on the SDAR itself, (Fig. 3), or can be retrieved through the radio. With both ESN's, the customer's Sirrus account number or phone number, customer's complete address in hand, call Sirrus at 888-539-7474, (to skip the recordings, press 1 then 3 and 3 again). Explain the transfer that needs to take place when the Sirrus agent answers. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Description and Operation Radio/Stereo Noise Filter: Description and Operation Radio noise suppression devices are factory-installed standard equipment on this vehicle. Radio Frequency Interference (RFI) and ElectroMagnetic Interference (EMI) can be produced by any on-board or external source of electromagnetic energy. These electromagnetic energy sources can radiate electromagnetic signals through the air, or conduct them through the vehicle electrical system. When the audio system converts RFI or EMI to an audible acoustic wave form, it is referred to as radio noise. This undesirable radio noise is generally manifested in the form of "buzzing," "hissing," "popping," "clicking," "crackling," and/or "whirring" sounds. In most cases, RFI and EMI radio noise can be suppressed using a combination of vehicle and component grounding, filtering and shielding techniques. This vehicle is equipped with factory-installed radio noise suppression devices that were designed to minimize exposure to typical sources of RFI and EMI; thereby, minimizing radio noise complaints. Factory-installed radio noise suppression is accomplished primarily through circuitry or devices that are integral to the factory-installed radios, audio power amplifiers and other on-board electrical components such as generators, wiper motors, blower motors, and fuel pumps that have been found to be potential sources of RFI or EMI. There are two common strategies that can be used to suppress Radio Frequency Interference (RFI) and ElectroMagnetic Interference (EMI) radio noise. The first suppression strategy involves preventing the production of RFI and EMI electromagnetic signals at their sources. The second suppression strategy involves preventing the reception of RFI and EMI electromagnetic signals by the audio system components. The use of braided ground straps in key locations is part of the RFI and EMI prevention strategy. These ground straps ensure adequate ground paths, particularly for high current components such as many of those found in the starting, charging, ignition, engine control and transmission control systems. An insufficient ground path for any of these high current components may result in radio noise caused by induced voltages created as the high current seeks alternative ground paths through components or circuits intended for use by, or in close proximity to the audio system components or circuits. Preventing the reception of RFI and EMI is accomplished by ensuring that the audio system components are correctly installed in the vehicle. Loose, corroded or improperly soldered wire harness connections, improperly routed wiring and inadequate audio system component grounding can all contribute to the reception of RFI and EMI. A properly grounded antenna body and radio chassis, as well as a shielded antenna coaxial cable with clean and tight connections will each help reduce the potential for reception of RFI and EMI. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams Right Remote Radio Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 8421 Remote Switch: Description and Operation Remote Radio Switch Operational View Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). These switches are resistor multiplexed units that are hard-wired to the Body Control Module (BCM) through the clockspring. The BCM sends the proper messages on the Programmable Communications Interface (PCI) data bus network to the radio receiver. For diagnosis of the BCM or the PCI data bus, the use of a DRB III(R) scan tool and the proper Diagnostic Procedures manual are recommended. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 8422 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Any diagnosis of the Audio system should begin with the use of the DRB III (R) diagnostic tool. 1. Disconnect and isolate the battery negative cable. Remote Radio Switches 2. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test 3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test table. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in drivers seat. 4. If the switch resistance checks OK, go to Step 5. If not OK, replace the faulty switch. 5. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open circuit as required. 6. Unplug the 24-way white wire harness connector from the Body Control Module (BCM). Check for continuity between the radio control circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to Step 7. If not OK, repair the short circuit as required. 7. Check for continuity between the radio control circuit cavities of the remote radio switch wire harness connector and the BCM wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures manual to test the BCM and the PCI data bus. If not OK, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 8423 repair the open circuit as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 8424 Remote Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag. 3. Remove the steering wheel. 4. Unplug the wire harness connector from the remote radio switch(es). 5. Remove three screws securing steering wheel rear cover. 6. Remove the remote radio switch from the steering wheel by depressing tabs on each side of each switch. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in drivers seat. INSTALLATION 1. Install remote radio switch to the steering wheel. 2. Install three screws securing steering wheel rear cover. 3. Connect the wire harness to the remote radio switch. 4. Install the steering wheel. 5. Install the driver side airbag. 6. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams Speaker: Diagrams Left Door Speaker Left Instrument Panel Speaker Left Rear Pillar Speaker (HighLine Audio) Right Door Speaker Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 8428 Right Instrument Panel Speaker Right Rear Pillar Speaker (Highline Audio) Right Rear Speaker Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 8429 Speaker: Testing and Inspection WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Any diagnosis of the Audio system should begin with the use of the DRB III(R) diagnostic tool. 1. If all speakers are inoperative, check the radio fuses in the Junction Block (JB). If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check the amplifier fuse (if equipped) in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 3. Turn the ignition switch to the ON position. Turn the radio receiver ON. Adjust the balance and fader control controls to check the performance of each individual speaker. Note the speaker locations that are not performing correctly. Go to Step 4. 4. Turn the radio receiver OFF. Turn the ignition OFF. Disconnect and isolate the battery negative cable. If vehicle is not equipped with a amplifier, remove the radio receiver. If vehicle is equipped with an amplifier, disconnect wire harness connector at output side of amplifier. Go to Step 4. 5. Check both the speaker feed (+) circuit and return (-) circuit cavities for the inoperative speaker at the radio receiver wire harness connector for continuity to ground. There should be no continuity. If OK, go to Step 5. If not OK, repair the shorted speaker feed (+) and/or return (-) circuits(s) to the speaker as required. 6. Disconnect wire harness connector at the inoperative speaker. Check for continuity between the speaker feed (+) circuit cavities of the radio receiver wire harness connector or if equipped, the amplifier wire harness connector and the speaker wire harness connector. Repeat the check between the speaker return (-) circuit cavities of the radio receiver wire harness connector and the speaker wire harness connector. In each case, there should be continuity. If OK, replace the faulty speaker. If not OK, repair the open speaker feed (+) and/or return (-) circuits(s) as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > D-Pillar Speaker Speaker: Service and Repair D-Pillar Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove rear header trim (right side speaker). 3. Remove jack cover (left side speaker). 4. Remove liftgate scuff plate. 5. Remove upper seat belt bolt. 6. Partially remove quarter trim panel to access the D-pillar speaker. D-Pillar Speaker 7. Slide the speaker from the retainer. 8. Disconnect the wire harness connector from the speaker. INSTALLATION 1. Connect the wire harness connector to the speaker. 2. Slide the speaker into the retainer. 3. Install quarter panel trim. 4. Install upper seat belt bolt (right side). 5. Install liftgate scuff plate. 6. Install rear header trim (right side). 7. Install jack cover (left side). 8. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > D-Pillar Speaker > Page 8432 Speaker: Service and Repair Front Door Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door trim panel. Door Speaker 3. Remove the speaker mounting screws. 4. Disconnect wire harness connector and remove speaker from door. INSTALLATION 1. Connect the wire harness connector and install speaker to door. 2. Install the speaker mounting screws. 3. Install the front door trim panel. 4. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > D-Pillar Speaker > Page 8433 Speaker: Service and Repair Instrument Panel Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the A-pillar trim. 3. Remove instrument panel top pad. Instrument Panel Speaker 4. Remove speaker screws. 5. Disconnect wire harness connector and remove speaker. INSTALLATION 1. Connect the wire harness connector and install speaker to instrument panel. 2. Install the speaker mounting screws. 3. Install instrument panel top pad. 4. Install A-pillar trim. 5. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > D-Pillar Speaker > Page 8434 Speaker: Service and Repair Quarter Panel Speaker REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the quarter trim bolster. Quarter Panel Speaker 3. Remove speaker retaining screws. 4. Disconnect wire harness connector and remove speaker. INSTALLATION 1. Connect the wire harness connector and install speaker to trim panel. 2. Install the speaker mounting screws. 3. Install quarter trim bolster. 4. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8440 Accessory Delay Relay: Description and Operation ACCESSORY RELAY The accessory relay is an electromechanical device that switches fused battery current to the accessory powered vehicle circuits when the ignition switch is turned to the Accessory or ON positions. The delay feature will maintain power to the accessories for 45 seconds after the ignition is shut OFF or until a door is opened. This allows sufficient time to close windows and park the windshield wipers. The accessory relay is located in the Integrated Power Module (IPM) in the engine compartment. The accessory relay is a International Standards Organization (ISO) relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The accessory relay cannot be repaired or adjusted and, if faulty or damaged, it must be replaced. The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When the electromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact. When the electromagnetic coil is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor or diode is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams Thatcham Alarm Module (united Kingdom) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 8444 Alarm Module: Service and Repair PROGRAMMING THE SENTRY KEY REMOTE ENTRY MODULE NOTE: If the PCM and the SKREEM are replaced at the same time program the VIN into the PCM first. All vehicle keys will then need to be replaced and programmed to the new SKREEM. 1. Turn the ignition on (transmission in park/neutral). 2. Use the DRBIII(R) and select THEFT ALARM SKREEM then MISCELLANEOUS. 3. Select SKREEM MODULE REPLACEMENT (GASOLINE). 4. Program the vehicle four-digit PIN into the SKREEM. 5. Select COUNTRY CODE and enter the correct country. NOTE: Be sure to enter the correct country code. If the incorrect country code is programmed into SKREEM the SKREEM must be replaced. 6. Select UPDATE VIN (the SKREEM will learn the VIN from the PCM). 7. Press ENTER to transfer the VIN (the PCM will send the VIN to the SKREEM). 8. The DRBIII(R) will ask if you want to transfer the secret key. Select ENTER to transfer secret key from the PCM. This will ensure the current vehicle ignition keys will still operate the SKREES system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Description and Operation Antenna Control Module: Description and Operation The antenna module is an electromagnetic circuit component designed to capture and enhance RF (Radio Frequency) signals in both the AM and FM broadcast bands. The antenna module is mounted to the right rear roof rail under the headliner. The module is grounded through the mounting bracket and fastener. The module has a two wire electrical connector that connects to the integral radio antenna,located on the right rear quarter glass. There is also an electrical connector for battery voltage and a coax cable connector. The antenna module receives both AM and FM radio signals supplied by the side window integral radio antenna system and selectively amplifies them. The amplified signal is then sent through the body length coax cable to the radio input. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Description and Operation > Page 8448 Antenna Module - Export Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Description and Operation > Page 8449 Antenna Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Antenna Module 2. Lower headliner as necessary to access antenna module. 3. Disconnect antenna coax cable lead and electrical harness connector from antenna module. 4. Disconnect the antenna module connector from the quarter glass. 5. Remove the mounting screw and the antenna module. INSTALLATION 1. Install the antenna module and the mounting fastener. 2. Connect the antenna connector to the quarter glass. 3. Connect the antenna lead and electrical connector to the antenna module. 4. Raise and install headliner. 5. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Ignition Shut Down Relay (For Antitheft) > Component Information > Description and Operation Ignition Shut Down Relay (For Antitheft): Description and Operation AUTO SHUT DOWN RELAY The relay is located in the Power Distribution Center (PDC). For the location of the relay within the PDC, refer to the PDC cover for location. Check electrical terminals for corrosion and repair as necessary The engine switched battery (NGC vehicles) informs the PCM when the ASD relay energizes. A 12 volt signal at this input indicates to the PCM that the ASD has been activated. This input is also used to power certain drivers on NGC vehicles. When energized, the ASD relay on NGC vehicles provides power to operate the injectors, ignition coil, generator field, O2 sensor heaters (both upstream and downstream), evaporative purge solenoid, EGR solenoid (if equipped) wastegate solenoid (if equipped), and NVLD solenoid (if equipped). The ASD relay also provides a sense circuit to the PCM for diagnostic purposes. If the PCM does not receive 12 volts from this input after grounding the control side of the ASD relay, it sets a Diagnostic Trouble Code (DTC). The PCM energizes the ASD any time there is an engine speed that exceeds a predetermined value (typically about 50 rpm). The ASD relay can also be energized after the engine has been turned off to perform an O2 sensor heater test, if vehicle is equipped with OBD II diagnostics. As mentioned earlier, the PCM energizes the ASD relay during an O2 sensor heater test. On NGC vehicles it checks the O2 heater upon vehicle start. The PCM still operates internally to perform several checks, including monitoring the O2 sensor heaters. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations > Page 8457 Keyless Entry Module: Connector Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations > Page 8458 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations > Page 8459 Steering Column Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations > Page 8460 Center Instrument Panel Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Component Locations > Page 8461 Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 8462 Sentry Key Remote Entry Module (Skreem) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 8463 Keyless Entry Module: Description and Operation The Sentry Key Remote Entry Module (SKREEM) performs the functions of the Sentry Key Immobilizer Module (SKIM), Remote Keyless Entry (RKE) Module, and the Tire Pressure Monitoring (TPM) System (previously part of the Electronic Vehicle Information Center (EVIC). The SKREEM is located in the same location as the SKIM was and is mounted the same way. It looks identical, but has added capabilities. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 8464 Keyless Entry Module: Testing and Inspection For proper diagnosis and testing of the Sentry Key Remote Entry Module (SKREEM), use a DRBIII (R) and refer to the proper Body Diagnostic Procedures information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 8465 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the Steering Column Opening Cover. 3. Remove the steering column upper and lower shrouds. 4. Disengage the steering column wire harness from the Sentry Key Remote Entry Module (SKREEM). 5. Remove the one screws securing the SKREEM to the steering column. 6. Rotate the SKREEM upwards and then to the side away from the steering column to slide the SKREEM antenna ring from around the ignition switch lock cylinder housing. 7. Remove the SKREEM from the vehicle. INSTALLATION 1. Slip the Sentry Key Remote Entry Module (SKREEM) antenna ring around the ignition switch lock cylinder housing. Rotate the SKREEM downwards and then towards the steering column. 2. Install the one screws securing the SKREEM to the steering column. 3. Connect the steering column wire harness to the SKREEM. 4. Install the steering column upper and lower shrouds. 5. Install the Steering Column Opening Cover. 6. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations Left Rear Body Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 8469 Park Assist Module (Parktronics) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 8470 Parking Assist Control Module: Description and Operation Park Assist Module Park Assist Module - Location The Park Assist Module is located on the left side of the vehicle, behind the quarter trim panel, just behind the C-pillar. It is has a molded plastic housing which housing internal circuitry and one electrical connector. There are two mounting tabs that affix the module to the left inner quarter panel with two screws. The module has a number of functions: - Supply voltage to the sensors and display. - Disconnection of the display with bus idle and over voltage Vmax. - Triggering the sensors. - Analyze echo delay times and calculate obstacle distances. - Bi-directional data communication to the display for diagnosis. - System diagnostics - diagnosis and error handling (sensors, display, module). - Data exchange over the Programmable Communication Interface (PCI) data bus. The module has a number of functions: - Supply voltage to the sensors and display. - Disconnection of the display with bus idle and over voltage Vmax. - Triggering the sensors. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 8471 - Analyze echo delay times and calculate obstacle distances. - Bi-directional data communication to the display for diagnosis. - System diagnostics - diagnosis and error handling (sensors, display, module). - Data exchange over the Programmable Communication Interface (PCI) data bus. The system detection length from the rear of the vehicle is 0.3 meters to 1.5 meters. This area extends around the rear side of the vehicle. The system detection height from the ground is 0.2 meters to about 1.5 meters. The radio mutes when the system activates its audible tone. When the driver selects Reverse, the system scans for objects behind the vehicle using four sensors located in the rear bumper. Objects can be detected from up to 1.5 meters. A warning display above the rear window provides both visible and audible warnings indicating the range of the object. The system is active only when the vehicle is in reverse for vehicle speeds less than 16 Km/h (10 mph). If the vehicles Parking/Emergency Brake is applied, the system is deactivated. The display contains two sets of yellow and red Light Emitting Diode's (LED's) that the driver can see as they look over their shoulder while backing up. Each side of the vehicle has its own warning LED's. The system provides a visual warning by illuminating one or more yellow LED's as the vehicle gets closer to the object. As the vehicle continues to approaches the object, one red LED is illuminated and the system emits a series of short beeps. The tone will remain constant and both red LED's are illuminated once the vehicle is within 12 inches (30.5 cm) of the object. The system can be turned ON or OFF through the Electronic Vehicle Information Center (EVIC) when the vehicle is in PARK. If the park assist system is turned OFF, a single chime will sound and the EVIC will display the following message "REAR PARK ASSIST OFF", when the vehicle is in reverse. - Ensure that the rear bumper is free of dirt and debris to keep the system operating properly. - Jackhammers, large trucks, and other vibrations could affect the performance of the system. - Ensure that the parking brake is not applied. If "Service Park Assist System" appears in the EVIC after making sure the rear bumper is clean, proceed to diagnose the system using a scan tool and the appropriate diagnostic information. To diagnose the Park Assist Module, use a scan tool and the appropriate body diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations > Page 8472 Parking Assist Control Module: Service and Repair REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Remove the left quarter trim panel. Park Assist Module Electrical Connector 4. Disconnect the Park Assist Module electrical connector. Park Assist Module Location 5. Remove the two attaching screws and separate the module from vehicle. INSTALLATION 1. Position the Park Assist Module and install the two attaching screws. Torque screws to 3.5 Nm (30 in. IDS.). 2. Connect the Park Assist Module electrical connector. 3. Install the left quarter trim panel. 4. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Locations > Page 8476 Pedal Positioning Module: Diagrams Memory Seat/Mirror/Adjustable Pedals Module C1 Memory Seat/Mirror/Adjustable Pedals Module C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Pedal Positioning Module > Component Information > Locations > Page 8477 Memory Seat/Mirror/Adjustable Pedals Module C3 Memory Seat/Mirror/Adjustable Pedals Module C4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Diagrams Voice Activation Module: Diagrams Hands Free Module C1 Hands Free Module C2 Hands Free Module C3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Diagrams > Page 8484 Voice Activation Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel lower console. Hands Free Module 3. Remove the mounting fasteners. 4. Disconnect the electrical harness connector and remove module. INSTALLATION 1. Connect electrical harness connector and position module. 2. Install mounting fasteners. 3. Install instrument panel lower console. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component Locations Hood Sensor/Switch (For Alarm): Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component Locations > Page 8493 Left Side Engine Compartment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 8494 Hood Sensor/Switch (For Alarm): Service and Repair HOOD AJAR SWITCH-EXPORT REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a small flat blade screwdriver, pry trigger switch from the bracket on the left fender well. 3. Disconnect the hood ajar switch from the wire connector and remove from vehicle. INSTALLATION 1. Connect the hood ajar switch to the wire connector. 2. Press the hood ajar switch into position on the bracket located on the left inner fender well. 3. Reconnect the battery negative cable. 4. Close the hood and check for proper operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations Lock Cylinder Switch: Locations Driver Door Passenger Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Locations > Page 8498 Right Cylinder Lock Switch (Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams Parking Assist Distance Sensor: Diagrams Park Assist Sensor No.7 (Parktronics) Park Assist Sensor No.8 (Parktronics) Park Assist Sensor No.9 (Parktronics) Park Assist Sensor No.10 (Parktronics) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 8502 Parking Assist Distance Sensor: Description and Operation Park Assist Sensor Park Assist Sensor Location The Park Assist Sensors are located in the rear bumper fascia mounted equally apart. The sensors generate ultrasonic pulses when triggered by the park assist module when an obstacle is detected. The sensors then signal the module when reflected ultrasonic pulses are received. The sensors detect objects with an ultrasonic pulse that reflects off the object and then is sent to the module to determine the distance of the object. The Park Assist Sensors: - Generate ultrasonic pulses when triggered by the Park Assist Module. - Reception/filtering of ultrasonic energy received. - Signalling the module of received ultrasonic pulses that meet threshold criteria. The sensors are supplied power by the module. The sensor supply is enabled when the sensor function is necessary. The sensors detection length from the rear of the vehicle is 0.3 meters to 1.5 meters. This area extends around the rear side of the vehicle. The sensor detection height from the ground is 0.2 meters to about 1.5 meters. - Ensure that the rear bumper (sensors) is free of dirt and debris to keep the system operating properly. - Jackhammers, large trucks, and other vibrations could affect the performance of the system. - Ensure that the parking brake is not applied. If "Service Park Assist System" appears in the EVIC after making sure the rear bumper is clean, proceed to diagnose the system using a scan tool and the appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Page 8503 Parking Assist Distance Sensor: Service and Repair REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. 3. Remove rear fascia. Sensor Retaining Clip 4. Remove the sensor retaining clip from the back side of the fascia. Sensor - Remove/Install 5. Push the Park Assist Sensor out of the fascia. INSTALLATION 1. Position the Park Assist Sensor over the retaining housing and firmly snap into housing in rear fascia. 2. Install the rear fascia. 3. Connect the battery negative cable. 4. Close hood. 5. Verify vehicle and system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Diagrams Adjustable Pedals Sensor (Memory Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 8510 Adjustable Pedals Switch (Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 8511 Pedal Positioning Switch: Service and Repair ADJUSTABLE PEDALS SWITCH REMOVAL The adjustable pedals switch is located in the steering column lower shroud. Remove the shroud, then remove the switch. INSTALLATION The adjustable pedals switch is located in the steering column lower shroud. Install the switch in the shroud, then install the shroud. Once installed, test for proper operation of the adjustable pedals. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams Right Remote Radio Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 8515 Remote Switch: Description and Operation Remote Radio Switch Operational View Two rocker-type switches (if equipped) are mounted on the back (instrument panel side) of the steering wheel spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player, CD player or CD changer (if equipped). These switches are resistor multiplexed units that are hard-wired to the Body Control Module (BCM) through the clockspring. The BCM sends the proper messages on the Programmable Communications Interface (PCI) data bus network to the radio receiver. For diagnosis of the BCM or the PCI data bus, the use of a DRB III(R) scan tool and the proper Diagnostic Procedures manual are recommended. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 8516 Remote Switch: Testing and Inspection WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Any diagnosis of the Audio system should begin with the use of the DRB III (R) diagnostic tool. 1. Disconnect and isolate the battery negative cable. Remote Radio Switches 2. Remove the remote radio switch(es) from the steering wheel. Remote Radio Switch Test 3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test table. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in drivers seat. 4. If the switch resistance checks OK, go to Step 5. If not OK, replace the faulty switch. 5. Check for continuity between the ground circuit cavity of the switch wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open circuit as required. 6. Unplug the 24-way white wire harness connector from the Body Control Module (BCM). Check for continuity between the radio control circuit cavity of the remote radio switch wire harness connector and a good ground. There should be no continuity. If OK, go to Step 7. If not OK, repair the short circuit as required. 7. Check for continuity between the radio control circuit cavities of the remote radio switch wire harness connector and the BCM wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures manual to test the BCM and the PCI data bus. If not OK, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 8517 repair the open circuit as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Page 8518 Remote Switch: Service and Repair WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO ELECTRICAL, RESTRAINTS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag. 3. Remove the steering wheel. 4. Unplug the wire harness connector from the remote radio switch(es). 5. Remove three screws securing steering wheel rear cover. 6. Remove the remote radio switch from the steering wheel by depressing tabs on each side of each switch. NOTE: The right remote radio switch back is white in color. The left switch back is black in color. The right/left remote radio switch orientation is with the steering wheel installed, and driver in drivers seat. INSTALLATION 1. Install remote radio switch to the steering wheel. 2. Install three screws securing steering wheel rear cover. 3. Connect the wire harness to the remote radio switch. 4. Install the steering wheel. 5. Install the driver side airbag. 6. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Ultrasonic Sensor, Antitheft > Component Information > Locations Ultrasonic Sensor: Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Ultrasonic Sensor, Antitheft > Component Information > Locations > Page 8522 Ultrasonic Sensor: Diagrams Front Intrusion Sensor (United Kingdom) Rear Instrusion Sensor (United Kingdom) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8528 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8529 Figure 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8530 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8531 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8532 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8533 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8534 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8535 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8536 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8537 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8538 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8539 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8540 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8541 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8542 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8543 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8544 Trailer Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and an Electrostatic Discharge Symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8545 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8546 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8547 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8548 Trailer Connector: Connector Views C318 (Trailer Tow) C318 (Trailer Tow) C319 (Trailer Tow) C319 (Trailer Tow) Trailer Tow Connector (Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8549 Trailer Connector: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-54-2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8550 8w-54-3 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8555 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8556 Figure 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8557 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8558 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8559 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8560 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8561 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8562 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8563 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8564 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8565 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8566 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8567 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8568 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8569 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8570 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8571 Trailer Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and an Electrostatic Discharge Symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8572 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8573 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8574 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8575 Trailer Connector: Connector Views C318 (Trailer Tow) C318 (Trailer Tow) C319 (Trailer Tow) C319 (Trailer Tow) Trailer Tow Connector (Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8576 Trailer Connector: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-54-2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8577 8w-54-3 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Diagrams Voice Activation Module: Diagrams Hands Free Module C1 Hands Free Module C2 Hands Free Module C3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Diagrams > Page 8582 Voice Activation Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel lower console. Hands Free Module 3. Remove the mounting fasteners. 4. Disconnect the electrical harness connector and remove module. INSTALLATION 1. Connect electrical harness connector and position module. 2. Install mounting fasteners. 3. Install instrument panel lower console. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set Body Control Module: Customer Interest Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set NUMBER: 08-028-05 GROUP: Electrical DATE: May 28, 2005 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD JULY, 2005. SUBJECT: Flash: MIL Illumination, Remote Keyless Entry (RKE) Inoperative OVERVIEW: This bulletin involves reprogramming the Body Control Module (BCM) with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to CS vehicles built on or before May 7, 2005 (MDH 0507XX) and RS vehicles, built on or between July 26, 2004 (MDH 0726XX) through and including May 7, 2005 (MDH 0507XX), with a 4-connector BCM. SYMPTOM/CONDITION: ^ MIL Illumination ^ RKE inoperative ^ PCI Internal Fault DTC in BCM DIAGNOSIS: 1. With the ignition switch in the "RUN" position, determine the original software part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R)" standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 8593 g. Record the "Software part # " on the repair order for later reference. h. Check DTC's 2. If the Symptom/Condition is present, use the following table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "BCM part # ", recorded in "Diagnosis Step # 1, in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 4. Select the flash file. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 8594 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm Body Control Module: Customer Interest Electrical - Locks Inoperative/Liftgate Triggers Alarm NUMBER: 08-040-04 GROUP: Electrical DATE: December 9, 2004 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD FEBRUARY, 2005. SUBJECT: Flash: Driver And Passenger Power Door Lock Switches Inoperative And Opening the Liftgate Triggers The Theft Alarm OVERVIEW: This bulletin involves selectively erasing and reprogramming the Body Control Module (BCM) with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to 2005 vehicles equipped with Power Locks only (sales code JPB) and 2004 2005 vehicles equipped with Power Locks, Power Liftgate, and Security Alarm (sales codes JPB, JRC and LSA respectively). SYMPTOM/CONDITION: The vehicle operator may describe: ^ The alarm sounds erroneously when opening the power liftgate using the key fob while the Vehicle Theft Alarm (VTA) is armed. ^ The driver's and/or passenger's door lock switches are inoperative. The technician may find "Left Unlock Output Failure" and/or "Right Unlock Output Failure" Diagnostic Trouble Codes (DTC's) in the BCM. DIAGNOSIS: 1. Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. With the ignition switch in the "RUN" position, determine the original part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" g. Record the "Software part # " on the repair order for later reference. h. Check DTC's Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm > Page 8599 3. If the vehicle operator describes or experiences the Symptom/Condition, use the table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "Software part # " recorded during "Diagnosis" in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 4. Select the calibration. 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest for Body Control Module: > 08-040-04 > Dec > 04 > Electrical - Locks Inoperative/Liftgate Triggers Alarm > Page 8600 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition to the "Run" position (engine not running). 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. 13. Verify that the problem cannot be repeated by cycling the ignition switch OFF/ON and actuating both door lock switches a few times. If any door lock failure still persists then further diagnosis is necessary. Verify the BCM "Software p/n" was updated to the new software p/n using Diagnosis Step # 2. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, PCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set Body Control Module: All Technical Service Bulletins Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set NUMBER: 08-028-05 GROUP: Electrical DATE: May 28, 2005 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD JULY, 2005. SUBJECT: Flash: MIL Illumination, Remote Keyless Entry (RKE) Inoperative OVERVIEW: This bulletin involves reprogramming the Body Control Module (BCM) with new software. MODELS: 2005 (CS) Pacifica 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to CS vehicles built on or before May 7, 2005 (MDH 0507XX) and RS vehicles, built on or between July 26, 2004 (MDH 0726XX) through and including May 7, 2005 (MDH 0507XX), with a 4-connector BCM. SYMPTOM/CONDITION: ^ MIL Illumination ^ RKE inoperative ^ PCI Internal Fault DTC in BCM DIAGNOSIS: 1. With the ignition switch in the "RUN" position, determine the original software part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R)" standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 8606 g. Record the "Software part # " on the repair order for later reference. h. Check DTC's 2. If the Symptom/Condition is present, use the following table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: REPAIR PROCEDURE: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "BCM part # ", recorded in "Diagnosis Step # 1, in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 4. Select the flash file. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-028-05 > May > 05 > Body Controls - MIL ON/Keyless Entry Inoperative/DTC Set > Page 8607 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-040-04 > Dec > 04 > Electrical Locks Inoperative/Liftgate Triggers Alarm Body Control Module: All Technical Service Bulletins Electrical - Locks Inoperative/Liftgate Triggers Alarm NUMBER: 08-040-04 GROUP: Electrical DATE: December 9, 2004 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL BE AVAILABLE ON ITIL/ISIS DVD FEBRUARY, 2005. SUBJECT: Flash: Driver And Passenger Power Door Lock Switches Inoperative And Opening the Liftgate Triggers The Theft Alarm OVERVIEW: This bulletin involves selectively erasing and reprogramming the Body Control Module (BCM) with new software. MODELS: 2004 - 2005 (RG) Chrysler Voyager (International Markets) 2004 - 2005 (RS) Town & Country/Caravan NOTE: This bulletin applies to 2005 vehicles equipped with Power Locks only (sales code JPB) and 2004 2005 vehicles equipped with Power Locks, Power Liftgate, and Security Alarm (sales codes JPB, JRC and LSA respectively). SYMPTOM/CONDITION: The vehicle operator may describe: ^ The alarm sounds erroneously when opening the power liftgate using the key fob while the Vehicle Theft Alarm (VTA) is armed. ^ The driver's and/or passenger's door lock switches are inoperative. The technician may find "Left Unlock Output Failure" and/or "Right Unlock Output Failure" Diagnostic Trouble Codes (DTC's) in the BCM. DIAGNOSIS: 1. Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures Manual, verify all systems are functioning as designed. If DTCs are present, other than those listed above, record them on the repair order and repair as necessary before proceeding further with this bulletin. 2. With the ignition switch in the "RUN" position, determine the original part number of the BCM currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone" b. "1998 - 2005 Diagnostics" c. "All (Except Below)" d. "Body Interior" e. "Body Computer" f. "Module Display" g. Record the "Software part # " on the repair order for later reference. h. Check DTC's Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-040-04 > Dec > 04 > Electrical Locks Inoperative/Liftgate Triggers Alarm > Page 8612 3. If the vehicle operator describes or experiences the Symptom/Condition, use the table to determine the appropriate action. SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII(R) connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE: NOTE: Whenever a controller is programmed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash should be restarted and then follow the directions on the DRBIII(R). 1. Before beginning the reprogramming procedure, remove any old flash reprogramming files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2 2. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 3. Enter the "Software part # " recorded during "Diagnosis" in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the available updates. 4. Select the calibration. 5. Select the "DRBIII" radio button which is next to the "Download/Update" button. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 08-040-04 > Dec > 04 > Electrical Locks Inoperative/Liftgate Triggers Alarm > Page 8613 6. Select the "Download/Update" button. 7. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 8. 8. Disconnect the DRBIII(R) from TechCONNECT. 9. Open the hood, install a battery charger and verify that the charging rate provides approximately 13.5 volts. 10. Connect the DRBIII(R) to the vehicle. 11. Turn the ignition to the "Run" position (engine not running). 12. Download the flash from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash" b. Follow the directions on the DRBIII(R) screen. 13. Verify that the problem cannot be repeated by cycling the ignition switch OFF/ON and actuating both door lock switches a few times. If any door lock failure still persists then further diagnosis is necessary. Verify the BCM "Software p/n" was updated to the new software p/n using Diagnosis Step # 2. NOTE: Due to the BCM programming procedure, a DTC may be set in other modules (TCM, PCM, MIC, SKIM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Component Locations Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 8616 Body Control Module: Connector Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 8617 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Component Locations > Page 8618 Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions Body Control Module: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8621 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8622 Figure 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8623 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8624 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8625 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8626 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8627 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8628 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8629 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8630 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8631 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8632 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8633 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8634 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8635 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8636 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8637 Body Control Module: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and an Electrostatic Discharge Symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8638 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8639 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8640 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8641 Body Control Module: Connector Views Body Control Module C1 Body Control Module C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8642 Body Control Module C3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8643 Body Control Module C4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8644 Body Control Module C5 (early Build) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8645 Body Control Module: Electrical Diagrams Non-memory Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8646 Memory Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8647 Occupant Restraint Controller - Highline Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8648 Occupant Restraint Controller - Lowline Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8649 Occupant Classification System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8650 Premium Audio System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8651 Base Audio System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8652 CD Changer DVD/CD Changer Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8653 Remote Radio Controls Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8654 Front ATC - LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8655 Front ATC - RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8656 Rear ATC - Three Zone Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8657 Diesel Cabin Heater Assist (DCHA) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8658 Communication Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8659 PCM Communication - NGC ECM And Cabin Heater Assist Communication - Diesel Only Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8660 Door Ajar System With Power Sliding Doors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8661 Door Ajar System Without Power Sliding Doors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8662 Exterior Lighting Horn System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8663 Ignition Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8664 Integrated Power Module/body Control Module Power And Grounds Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8665 Instrument Cluster - Base Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8666 Instrument Cluster And Message Center (export, LHD) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8667 Instrument Cluster And Message Center (export,RHD) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8668 Interior Lighting Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8669 Base Manual Temperature Control System, LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8670 Base Manual Temperature Control System. RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8671 Dual-zone And Three Zone(front) Manual Temperature Control System, LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8672 Dual-zone Zone(front) Manual Temperature Control System, RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8673 Three Zone Rear Manual Temperature Control System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8674 Front Blower Motor - RS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8675 Front Blower Motor - RG Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8676 Rear Blower Motor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8677 Memory System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8678 Overhead Console Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8679 Park Assist Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8680 Power Door Looks/RKE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8681 LHD (export Only) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8682 RHD (export Only) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8683 Power Liftgate System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8684 Lift Power Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8685 Right Power Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8686 Power Sliding Door And Liftgate Switches Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8687 Rear Defog/Heated Mirror Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8688 Hands Free Phone - With CD Changer Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8689 Hands Free Phone - With CD/DVD Changer Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8690 Vehicle Theft Security System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8691 Thatcam Alarm System (export Only) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8692 Wipers - Front And Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8693 A/C - Lef Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8694 Le - Tr 8W-45-2 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8695 8w-45-2 Next Diagram See: 8W-45-3 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-3 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8696 8w-45-3 Next Diagram See: 8W-45-4 Previous Diagram See: 8W-45-2 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8697 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-4 Next Diagram See: 8W-45-5 Previous Diagram See: 8W-45-3 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8698 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-5 Next Diagram See: 8W-45-6 Previous Diagram See: 8W-45-4 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8699 8W-45-6 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-6 Next Diagram See: 8W-45-7 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8700 Previous Diagram See: 8W-45-5 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-7 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8701 8w-45-7 Next Diagram See: 8W-45-8 Previous Diagram See: 8W-45-6 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-8 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8702 8w-45-8 Next Diagram See: 8W-45-9 Previous Diagram See: 8W-45-7 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8703 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-9 Next Diagram See: 8W-45-10 Previous Diagram See: 8W-45-8 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8704 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-10 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8705 Next Diagram See: 8W-45-11 Previous Diagram See: 8W-45-9 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-11 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8706 8w-45-11 Next Diagram See: 8W-45-12 Previous Diagram See: 8W-45-10 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-12 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8707 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-12 Next Diagram See: 8W-45-13 Previous Diagram See: 8W-45-11 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8708 Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-13 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-13 Next Diagram See: 8W-45-14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8709 Previous Diagram See: 8W-45-12 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-14 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8710 8w-45-14 Next Diagram See: 8W-45-15 Previous Diagram See: 8W-45-13 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8711 8W-45-15 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-15 Next Diagram See: 8W-45-16 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8712 Previous Diagram See: 8W-45-14 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-16 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8713 8w-45-16 Next Diagram See: 8W-45-17 Previous Diagram See: 8W-45-15 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-17 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8714 8w-45-17 Next Diagram See: 8W-45-18 Previous Diagram See: 8W-45-16 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-18 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-18 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8715 Next Diagram See: 8W-45-19 Previous Diagram See: 8W-45-17 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-19 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8716 8w-45-19 Next Diagram See: 8W-45-20 Previous Diagram See: 8W-45-18 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number 8W-45-20 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8717 PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-45-19 Previous Diagram See: 8W-45-19 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8718 Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information Body Control Module: Technician Safety Information SERVICING SUB-ASSEMBLIES Some components of the body system are intended to be serviced as an assembly only. Attempting to remove or repair certain system subcomponents may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service Precautions > Technician Safety Information > Page 8721 Body Control Module: Vehicle Damage Warnings Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. When testing voltage or continuity at any control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description Body Control Module: Description and Operation System Description IDENTIFICATION OF SYSTEM The vehicle systems that are part of the body system are: - Adjustable Pedal System (APS) - Airbag System - Audio - Automatic Temperature Control - Cabin Heater - Chime - Communication - Door Ajar System - Electrically heated system - Exterior lighting - Instrument Cluster - Interior Lighting - Manual Temperature Control - Memory Seat - Overhead Console - Park Assist - Power Door Lock/RKE - Power Folding Mirrors - Power Sliding Doors - Power Liftgate - Power windows - Telecommunications (hands free phone) - Tire Pressure Monitor System (TPMS) - Vehicle Theft Security System (VTSS) - Windshield Wiper and Washer SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION The body system on the 2005 RS and RG consists of a combination of modules that communicate over the PCI bus (Programmable Communication Interface multiplex system). Through the PCI bus, information about the operation of vehicle components and circuits is relayed quickly to the appropriate modules. All modules receive all the information transmitted on the bus even though a module may not require all information to perform its function. It will only respond to messages addressed to it through binary coding process. This method of data transmission significantly reduces the complexity of the wiring in the vehicle and the size of wiring harnesses. All of the information about the functioning of all the systems is organized, controlled, and communicated by the PCI bus, which is described in the Communication Section of this general information. The Body Control Module (BCM) is located in the passenger compartment, attached to the bulkhead underneath the left side of the instrument panel. The BCM utilizes integrated circuitry and information carried on the Programmable Communications Interface (PCI) data bus network along with many hard wired inputs to monitor many sensor and switch inputs throughout the vehicle. In response to those inputs, the internal circuitry and programming of the BCM allow it to control and integrate many electronic functions and features of the vehicle through both hard wired outputs and the transmission of electronic message outputs to other electronic modules in the vehicle over the PCI data bus. The Body Control Module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the BCM is interfaced to the vehicle's serial bus communications network, referred to as the Programmable Communications Interface (PCI) bus. This network consists of the; - Powertrain Control Module (PCM) - Transmission Control Module (TCM) - Mechanical Instrument Cluster (MIC) - Occupant Restraint Controller (ORC) - Compass/Mini-Trip Computer (CMTC) - Electronic Vehicle Information Center (EVIC) - Controller Antilock Brake (CAB) - HVAC Control Module - Sliding Door Control Modules (driver and passenger side doors) - Power Liftgate Module (PLG) - Audio system equipped with RAZ, RBU, RBK, and RBB radios. - Sentry Key Remote Entry Module (SKREEM). - Side Impact Airbag Control Module (SIACM) - Memory Seat Module (MSM) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8724 - Sentry Key Immobilizer Module (SKIM) The BCM is operational when battery power is supplied to the module. The BCM provides the following features: - Power Door Locks - Automatic Door Locks - Battery Protection - The BCM will automatically turn off all exterior lamps after 3 minutes, and all interior lamps after 15 minutes after the ignition is turned off, if they are not turned off by the driver. - Chime Control - Compass/Mini-Trip support. - Interior Lighting (Courtesy/Reading Lamps) - BCM Diagnostic Reporting - Electronic Liftgate Release (with Power Door Locks) - Exterior Lighting - Headlamp Time Delay (with/without Automatic Headlamps) - Illuminated Entry - Fade to Off Interior Lamps - This feature dims the interior lighting (courtesy lamps) gradually if the BCM does not receive any new inputs that would cause the interior lamps to remain on. - Pulse Width Modulated Instrument Panel Dimming - Door Lock Inhibit - This feature disables the door lock functions if the key is in the ignition and either front door is ajar. Pressing the Remote Keyless Entry (RKE) lock/unlock button under these conditions result in normal lock/unlock activation. Learned Features The BCM has the ability to LEARN additional features in the vehicle, provided the appropriate switch input and PCI data bus messages are received. Refer to the LEARNED FEATURES table. When replacing a BCM there are three modules available: - Base - Midline - RG - Export Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8725 The Midline controller is used on vehicles that have Power Door Locks. If a vehicle is equipped with the Vehicle Theft Security System, the Midline controller becomes a Premium when the theft feature is enabled. CAUTION: Do not swap Body Control Modules between vehicles or body controller's off the shelf. The BCM has internal diagnostic capability that assists in diagnosing the system error. When an OPEN or a SHORT circuit exists, the diagnostic tool can be used to read the BCM faults. The faults are very descriptive in identifying the appropriate feature that has faulted. The only two faults that the BCM logs that conclude the replacement of a BCM are faults; - # 01 - Internal BCM failure (replace BCM) - # 1F - J1850 Internal Hardware Failure (replace BCM) Otherwise the appropriate diagnostic procedures for each of the features should be taken when the BCM logs a fault. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8726 Body Control Module: Description and Operation Functional Operation Adjustable Pedals System The Adjustable Pedals are designed to enable the fore and aft repositioning of the brake and accelerator pedals. This results in improved ergonomics in relation to the steering wheel for taller and shorter drivers. Being able to adjust the pedal positions also allows the driver to set steering wheel tilt and seat positions to the most comfortable position available. The positions can be adjusted without compromising safety or comfort in actuating the pedals. Repositioning the pedals does not change the effort required for actuation. Changing of pedal position is accomplished by means of a motor. Operating the adjustable pedal switch activates the pedal drive motor. The pedal drive motor changes the position of the brake and accelerator pedals. The pedal can move rearward or forward. The pedals are moved to a position that is most comfortable for the driver. The accelerator and brake pedals are moved at the same rate to ensure synchronization. Neither the motor nor mechanisms are subject to mechanical stress of brake or accelerator application. The adjustable pedals feature is available on a non-memory/memory-equipped vehicle. The non-memory system consists of a mechanical switch that allows pedal travel adjustment. The IPM controls the Fused B+ circuit voltage to the adjustable pedals switch through the adjustable pedals relay. The circuit opens when the IPM detects an active cruise control state or when the vehicle is in reverse. The adjustable pedals control switch is located on the right side steering column shroud. The switch is hardwired directly to the adjustable pedals motor. When the operator actuates the switch to adjust the pedals, voltage is applied to the adjustable pedals motor allowing adjustment. The memory system, known as the Memory Seat Mirror Adjustable Pedal Module (MSMAPM), is located under the driver's seat and controls the adjustable pedals. The adjustable pedals control switch is located on the right side steering column shroud. The switch is hardwired directly to the MSMAPM. When the operator actuates the switch to adjust the pedals, the MSMAPM controls the adjustable pedals motor movement with input from the adjustable pedals sensor. This sensor allows pedal adjustment and memory functions to be recalled from the driver door mounted memory buttons or the RKE transmitters. The adjustable pedals will not operate when in an active cruise control state or when the vehicle is in reverse. Part 1 of 2 AIRBAG SYSTEM/OCCUPANT RESTRAINT CONTROLLER SYSTEM AND OCCUPANT CLASSIFICATION SYSTEM The Airbag System contains the following components: Occupant Restraint Controller (ORC), Air-bag Warning Indicator, Clockspring, Driver and Passenger dual squib Airbags, Driver and Passenger Seat belt Tensioner (SBT), Driver and Passenger Hall-effect Seat Belt Buckle Switches (SBS), Left and Right Side Curtain Airbags, and Front and Side Impact Sensors. The ORC also monitors the Occupant Classification System (OCS) for the presence of a passenger in the front outer seat. The Occupant Classification System contains the following components: Occupant Classification Module (OCM), Bladder and Sensor, Belt Tension Sensor, and Passenger Airbag off Indicator. The Occupant Restraint Controller (ORC) supports staged airbag deployment and remote impact sensing. Staged deployment is the ability to trigger airbag system squib inflators individually as needed to provide the appropriate restraint for the severity of the impact. The ORC has four major functions: PCI Bus communications, onboard diagnostics, impact sensing, and component deployment. The ORC also contains an energy-storage capacitor. This capacitor stores enough electrical energy to deploy the front airbag components for two seconds following a battery disconnect or failure during an impact. The ORC is secured to the floor panel transmission tunnel below the instrument panel inside the vehicle. The ORC cannot be repaired or adjusted. The ORC sends and/or receives PCI Bus messages with the Instrument Cluster (MIC), Body Control Module (BCM), and Powertrain Control Module (PCM). Diagnostic trouble codes will be set if the communication with these modules is lost or contains invalid information. The microprocessor in the ORC monitors the front impact sensor signals and the airbag system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sends a message to the instrument cluster via PCI bus to turn on the Airbag Warning Indicator. The ORC can set both active and stored diagnostic trouble codes to aid in diagnosing system problems. See DIAGNOSTIC TROUBLE CODES. The ORC uses an internal accelerometer, two front sensors and six side impact sensors, to sense the rate of vehicle deceleration and provide verification of the direction and severity of an impact. A pre-programmed decision algorithm in the ORC microprocessor determines when the deceleration rate is severe enough to require airbag system protection. The ORC also uses the driver and passenger seat belt switch status (buckled or unbuckled) to determine the level of driver airbag deployment, low medium or high. When the programmed conditions are met, the ORC sends an electrical signal to deploy the appropriate airbag system components. WARNING: - THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS CAN RESULT IS ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. - NEVER STRIKE OR KICK THE OCCUPANT RESTRAINT CONTROLLER, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. The Airbag Warning Indicator is the only point at which the customer can observe symptoms of a system malfunction. Whenever the ignition key is Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8727 turned to the run or start position, the ORC performs a lamp check by turning the Airbag Warning Indicator on for 6-8 seconds. After the lamp check, if the indicator turns off, it means that the ORC has checked the system and found it to be free of discernible malfunctions. If the lamp remains on, there could be an active fault in the system or the MIC lamp circuit may be internally shorted. If the lamp comes on and stays on for a period longer than 6-8 seconds then goes off, there is usually an intermittent problem in the system. DRIVER AIRBAG The airbag protective trim cover is the most visible part of the driver side airbag system. The protective trim cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. The module is mounted directly to the steering wheel. Located under the trim cover are the horn switch, the airbag cushion, and the airbag cushion supporting components. When supplied with the proper electrical signal, the inflator or inflators discharge the gas directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE DRIVER AIRBAG MODULE CONTAINS ARGON GAS PRESSURIZED TO OVER 17236.89 kPa (2500 PSI). DO NOT ATTEMPT TO DISMANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. CAUTION: Deployed Front Air Bags may or may not have live pyrotechnic material within the air bag inflator. Do not dispose of Driver and Passenger Airbags unless you are sure of complete deployment. Please refer to the Hazardous Substance Control System for Proper Disposal. Dispose of deployed air bags in a manner consistent with state, provincial, local, and federal regulations. Use the following table to identify the status of the Airbag Squib. AIRBAG SQUIB STATUS 1. Using a DRBIII(R) read Airbag DTC's If the following active codes are present: If neither of the following codes is an active code: ACTIVE DTC SQUIB STATUS Driver squib 1 open Driver Squib 2 open Status of Airbag is Unknown. CLOCKSPRING The clockspring is mounted on the steering column under the steering wheel. This assembly consists of a plastic housing which contains a flat, ribbon-like, electrically conductive tape that winds and unwinds with the steering wheel rotation. The clockspring is used to maintain a continuous electrical circuit between the instrument panel wiring and the driver airbag, the horn, and the vehicle speed control switches if equipped. The clockspring Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8728 must be properly centered when it is reinstalled on the steering column following any service procedure, or it could be damaged. The clockspring cannot be repaired and it must be replaced. PASSENGER AIRBAG The front passenger airbag is equipped with dual stage squib inflators. When supplied with the proper electrical signal the inflator or inflators discharge the gas directly into the cushion. The airbag module cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: THE PASSENGER AIRBAG MODULE CONTAINS INERT GAS PRESSURIZED TO 17236.89 kPa (2500 PSI). DO NOT ATTEMPT TO IS MANTLE AN AIRBAG MODULE OR TAMPER WITH ITS INFLATOR.DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURE EXCEEDING 93° C (200° F). REPLACE AIRBAG SYSTEM COMPONENTS ONLY WITH PARTS SPECIFIED IN THE MOPAR PARTS CATALOG. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE MOPAR PARTS CATALOG. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. AIRBAG SQUIB STATUS 1. Using a DRBIII(R) read Airbag DTC's If the following active codes are present: If neither of the following codes is an active code: ACTIVE DTC SQUIB STATUS Passenger squib 1 open Passenger squib 2 open Status of Airbag is Unknown. CAUTION: Deployed Front Air Bags may or may not have live pyrotechnic material within the air bag inflator. Do not dispose of Driver and Passenger Airbags unless you are sure of complete deployment. Please refer to the Hazardous Substance Control System for Proper Disposal. Dispose of deployed air bags in a manner consistent with state, provincial, local, and federal regulations. Use the following table to identify the status of the Airbag Squib. SEAT BELT TENSIONER (SBT) The driver and passenger seat belt (buckle) tensioners are mounted to the inboard side of the front seats. The seat belt buckle and seat belt switch are connected directly to the seat belt tensioner cable. At the onset of an impact event the ORC uses the seat belt tensioner to rapidly retract the seat belt buckles. With the slack removed, the occupant's forward motion in an impact will be reduced as will the likelihood of contacting interior components. The seat belt tensioner cannot be repaired, if damaged or defective it must be replaced. The ORC continuously monitors the resistance of the seat belt tensioner circuits for open and shorted conditions. SEAT BELT SWITCHES (SBS) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8729 The hall-effect driver and passenger seat belt switches provide the seat belt status, buckled or unbuckled, via hardwired inputs to the ORC. If the seat belt switch is damaged or defective the seat belt tensioner must be replaced. The ORC continuously monitors the seat belt switch circuits for open and shorted conditions. DRIVER KNEE BLOCKER AIRBAG The most visible part of the Driver Knee Blocker Airbag is the knee blocker trim cover. The knee blocker trim cover and airbag are mounted directly to the instrument panel structure below the steering column. When supplied with the proper electrical signal, the inflator discharges the gas directly into the airbag. The airbag cannot be repaired, and must be replaced if deployed or in any way damaged. WARNING: - DO NOT ATTEMPT TO MODIFY ANY PART OF YOUR ADVANCED AIRBAG SYSTEM. THE AIRBAG MAY INFLATE ACCIDENTALLY OR MAY NOT FUNCTION PROPERLY IF MODIFICATIONS ARE MADE. TAKE YOUR VEHICLE TO AN AUTHORIZED DEALER FOR ANY ADVANCED AIRBAG SYSTEM SERVICE. IF YOU'RE SEAT INCLUDING YOUR TRIM COVER AND CUSHION NEEDS TO BE SERVICED IN ANY WAY (INCLUDING REMOVAL OR LOOSENING/TIGHTENING OF EAT ATTACHMENT BOLTS), TAKE THE VEHICLE TO YOUR AUTHORIZED DEALER. ONLY MANUFACTURER APPROVED SEAT ACCESSORIES MAY BE USED. CONTACT YOUR AUTHORIZED DEALER IF IT IS NECESSARY TO MODIFY AN ADVANCED AIRBAG SYSTEM FOR PERSONS WITH DISABILITIES. - NEVER STRIKE OR KICK THE AIRBAG CONTROL MODULE, AS IT CAN DAMAGE THE IMPACT SENSOR OR AFFECT ITS CALIBRATION. IF AN AIRBAG CONTROL MODULE IS ACCIDENTALLY DROPPED DURING SERVICE, THE MODULE MUST BE SCRAPPED AND REPLACED WITH A NEW UNIT. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. FRONT AND SIDE IMPACT SENSOR The front and side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, and combined with the ORC Accelerometer Sensor provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller. The ORC microprocessor continuously monitors all of the front and side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a system fault, it sets a Diagnostic Trouble Code and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor signal and ground circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor signal circuit. If the sensor is dropped it must be replaced. CAUTION: Do not remove or install the impact sensors while the sensor is connected to the vehicle wiring. OCCUPANT CLASSIFICATION SYSTEM A non-calibrated Occupant Classification Module (OCM) is the only component of the Occupant Classification System (OCS) that is available for separate service replacement, as outlined in the procedures that follow. The OCS components of the passenger side front seat cushion including the cushion frame, springs, pad, seat weight bladder and pressure sensor, seat cushion foam and the OCM are a factory-calibrated and assembled unit. Once this unit is connected to a vehicle electrically, the calibration settings are uploaded from the OCM and stored in the memory of the Airbag Control Module (ORC). If only the OCM is subsequently replaced, the new, non-calibrated OCM learns the proper calibration settings from the ORC after it is connected to the vehicle electrically. If any of the remaining OCS components of the passenger side, front seat cushion require replacement, they are serviced only as a factory calibrated, assembled, and tamper-evident service replacement package. This package includes the assembled frame, springs, pad, seat weight bladder and pressure sensor, foam, wiring and a calibrated OCM. When installing this package, always replace all of the existing components with the new components as a unit. Do not attempt to separate or disconnect any of the new OCS components contained in the service replacement package from each other, and do not attempt to reuse any of the replaced components in this or any other vehicle. Once any of the original factory-installed components except the OCM have been replaced with the service replacement package components, the OCM can only be serviced by replacing the entire passenger side front seat cushion unit with another complete service replacement package. CAUTION: On vehicles equipped with the Occupant Classification System (OCS), never replace both the Airbag Control Module (ORC) and the Occupant Classification Module (OCM) at the same time. If both require replacement, replace one. Then perform the supplemental restraint verification test before replacing the other. Both the ORC and the OCM store OCS calibration data, which they transfer to one another when one of them is replaced. If both are replaced at the same time, an irreversible fault will be set in both modules. The OCM is subsystem of the Airbag Control Module (ORC). Therefore the OCM bus message updates the ORC with the front passenger seat information via PCI Bus message. The ORC then controls the Passenger Off indicator and the Airbag Warning Indicator to provide system onboard diagnostic feedback. All OCS wiring repairs are prohibited; when wiring problems are diagnosed a Bladder Repair Kit is the only approved repair. Part 2 of 2 PASSENGER AIRBAG OFF INDICATOR Vehicles equipped with the Occupant Classification System (OCS) include a passenger airbag off indicator located in the Switch Bank in the center of the instrument panel. Vehicles without OCS have a blank lens installed in the instrument panel. At ignition on, for a system test, the ORC low side driver grounds a yellow Light Emitting Diode (LED) circuit causing the PASS AIRBAG OFF Indicator text and icon to be illuminated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8730 SEAT WEIGHT SENSOR Vehicles equipped with the Occupant Classification System (OCS) have a seat weight bladder and pressure sensor unit that is integral to the passenger front seat cushion. The pressure sensor receives a nominal five volts and a ground through dedicated hardwired circuits from the OCM. The OCM then monitors the pressure sensor output voltage. SEAT BELT TENSION SENSOR - BTS The Belt Tension Sensor (BTS) is designed to measure belt tension as an input to a passenger Occupant Classification System (OCS). It is used to detect high cinch loads associated with child seats and compensate for the seat cushion load to correctly classify occupant size. When a load is applied to the seat belt, the belt tension sensor measures the load. As the load changes, the circuitry of the belt tension sensor changes the output voltage of the sensor. The belt tension sensor receives a nominal five volts and a ground through dedicated hardwired circuits from the OCM. The OCM then monitors the belt tension sensor output voltage on a dedicated hardwired data communication circuit. If the vehicle has experienced any impact(s) resulting in deployment of a pyrotechnic device of any kind (airbag, seatbelt tensioner, side curtain, etc.) within the vehicle, the entire passenger seat belt retractor assembly, including the BTS, shall be replaced. Additionally, if the seat belt webbing has become cut, frayed, or worn; or if the stitching has become damaged in any way, the entire passenger seat belt retractor assembly, including the BTS, shall be replaced. The belt tension sensor cannot be repaired and, if faulty or damaged, the entire passenger side front seat belt and retractor unit must be replaced. The OCM Verification Test will also provide a BTS Verification procedure to verify the BTS function. This verification procedure requires the Miller Special Tool #8828. BLADDER REPAIR KIT There are only three replaceable components in the OCS, Occupant Classification Module, Bladder Repair Kit and the Passenger Airbag OFF Indicator. The Bladder repair kit contains the OCS bladder, wire harnesses, pressure sensor (Seat Weight Sensor), module, seat cushion and other related structural and sound deadening components. The module and sensor connector must have a Tamper Evident material installed on the service kit module and sensor connectors. This material provides visible evidence that the assembly has been separated after the calibration process was completed. Do not install a Bladder Repair Kit if it appears that any of the components have been disconnected. The OCM can be replaced if the Airbag Control Module has uploaded the seat calibration into memory in a previous ignition cycle and the new OCM has a blank VIN and no calibration data stored in memory. NOTE: - An OCM can only be replaced in a passenger front seat if the seat is equipped with the original OCS module, bladder, sensor and wiring. - Servicing the OCS may create additional active and stored trouble codes that must be resolved before the vehicle can be returned to the owner. The OCS Verification Test will also set active DTC's if the procedure is not completed successfully. The Miller Special Tool, MRL-9077 and the DRBIII are needed to successfully complete the system Verification Test. The DRBIII(R) may report the following NEW DRBIII(R) FEATURE ORC Menu The DRBIII(R) ORC System Test screen will display the following: 2VIN verification - Original VIN and Current VIN 2PCM Monitor - PCM Active On The Bus or PCM Not Active On The Bus The DRBIII(R) ORC Input/Outputs screen will display the following: - OCM Status: Seat Class 0 (Empty) - Seat Cass 1 (Rear Facing Infant car Seat or RFIS) - Seat Class 2 (6 year old or Child) - Seat Class 3 (greater than or equal to 5th Percentile Female) - Seat Class 4 (less than 5th Percentile Female) - Seat Class 5 (Undetermined) The DRBIII(R) ORC Miscellaneous screen will display the following: - Configure Airbag On-Off Switch 1. No Airbag On-Off Switch 2. Pass OCM Only OCS Menu The DRBIII(R) OCM Input/Output screen will display the following: - OCS Status - 90, 919, 929, 939, 949, 959 The DRBIII(R) OCM Sensors screen will display the following: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8731 - Bladder Output - XXX A/D counts - Pas BTS Output - XXX A/D counts The DRBIII(R) OCM OCS Info Monitor screen will display the following: - Pass BTS -- Enabled or Disabled System Verification The DRBIII(R) OCM System Test screen will display the following: - PCM Monitor - PCM Active On The Bus or PCM Not Active On The Bus - Clear VIN Mismatch - Clear VIN Mismatch Complete - VIN Verification - Original VIN and Current VIN Clear VIN Mismatch - OCS Verification - OCS Verification Test process errors: Test In Progress Mode 33 Not Supported Subfunction not supported Test Busy - Repeat Test Conditions for Test Not Correct Routine Already Running Routine was Never Started Press any key to continue, then restart the verification test. Test failed conditions: Test Failed - Active DTC's Present Test Failed - Seat is Empty Test Failed - Seat Occupied Test Failed - Weight Above Threshold Test Failed - Weight Below Threshold Test Failed - Temperature Out of Range Test Failed - Seat Pressure Too High Test Failed - Seat Pressure Too Low Test Failed - Seat Pressure Not Stable Test Failed - Temperature Out of Range Test Failed - Seat Pressure Too Low Test Failed - Power Up Time Too Short Test Failed - Power Up Time Too Long Test Failed - K Empty Count is 0 Test Failed - No EOL Calibration Test Failed - K Allow is FF Allow the vehicle seat and interior temperature to stabilize, check voltage supplies and repair any other active DTC's before restarting the System Verification test. The OCS has been Verified or The OCS has NOT been Verified WARNING: - TO AVOID PERSONAL INJURY OR DEATH, TURN THE IGNITION OFF, DISCONNECT THE BATTERY AND WAIT TWO MINUTES BEFORE PROCEEDING. - TO AVOID PERSONAL INJURY OR DEATH, TURN THE IGNITION ON, THEN RECONNECT THE BATTERY. - TO AVOID PERSONAL INJURY OR DEATH ON VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS), ONLY THE OCCUPANT CLASSIFICATION MODULE (OCM) AND THE PASSENGER SEAT BLADDER AND CUSHION SERVICE KIT ARE THE ONLY PARTS SERVICED. - IF THE OCCUPANT CLASSIFICATION MODULE IS DROPPED AT ANY TIME, IT MUST BE REPLACED. FAILURE TO TAKE THE PROPER PRECAUTIONS CAN RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND PERSONAL INJURY OR DEATH. TO AVOID PERSONAL INJURY OR DEATH ON VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS), ONLY THE OCCUPANT CLASSIFICATION MODULE (OCM) AND THE SEAT CUSHION TRIM MAY BE SERVICED SEPARATELY. ALL OTHER COMPONENTS OF THE PASSENGER SIDE FRONT SEAT CUSHION ASSEMBLY MUST BE SERVICED ONLY AS A COMPLETE FACTORY-CALIBRATED, ASSEMBLED AND TAMPER-EVIDENT SERVICE REPLACEMENT PACKAGE. THIS PACKAGE INCLUDES THE FRAME, SPRINGS, PAD, BLADDER AND PRESSURE SENSOR, FOAM, WIRING AND A CALIBRATED OCM. WHEN INSTALLING THIS PACKAGE ALWAYS REPLACE ALL OF THE EXISTING COMPONENTS WITH THE NEW COMPONENTS AS A UNIT. DO NOT ATTEMPT TO SEPARATE OR DISCONNECT Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8732 ANY OF THE NEW OCS COMPONENTS IN THE SERVICE REPLACEMENT PACKAGE FROM EACH OTHER, AND DO NOT ATTEMPT TO REUSE ANY OF THE REPLACED COMPONENTS IN THIS OR ANY OTHER VEHICLE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN FAILURE OF THE PASSENGER AIRBAG TO DEPLOY WHEN REQUIRED, OR IN PASSENGER AIRBAG DEPLOYMENT WHEN NOT REQUIRED. SPECIAL TOOLS Some airbag diagnostic tests will require the use of special tools, airbag load tools, 8443 for testing squib circuits and the Occupant Classification Seat Weight Tool 9077. The load tools contain fixed resistive loads, jumpers and adapters. The fixed loads are connected to cables and mounted in a storage case. The cables can be directly connected to some airbag system connectors. Jumpers are used to convert the load tool cable connectors to the other airbag system connectors. The adapters are connected to the module harness connector to open shorting clips and protect the connector terminal during testing. When using the load tool follow all of the safety procedures in the service information for disconnecting airbag system components. Inspect the wiring, connector and terminals for damage or misalignment. Substitute the airbag load tool in place of a Driver or Passenger Airbag, curtain airbag, clockspring, or seat belt tensioner (use a jumper if needed). Then follow all of the safety procedures in the service information for connecting airbag system components. Read the module active DTC's. If the module reports NO ACTIVE DTC's the defective component has been removed from the system and should be replaced. If the DTC is still active, continue this process until all components in the circuit have been tested. Then disconnect the module connector and connect the matching adapter to the module connector. With all airbags disconnected and the adapter installed the squib wiring can be tested for open and shorted conditions. DIAGNOSTIC TROUBLE CODES Airbag diagnostic trouble codes consist of active and stored codes. If more than one code exists, diagnostic priority should be given to the active codes. Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of the trouble codes. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes with the DRBIII(R). This will direct you to the specific test(s) that must be performed. In certain test procedures diagnostic trouble codes are used as a diagnostic tool. ACTIVE CODES The code becomes active as soon as the malfunction is detected or key-on, whichever occurs first. An active trouble code indicates an on-going malfunction. This means that the defect is currently there every time the Occupant Restraint Controller checks that circuit or component. It is impossible to erase an active code. Active diagnostic trouble codes for the airbag system are not permanent and will change the moment the reason for the code is corrected. With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is detected, the airbag lamp remains lit for a minimum of 12 seconds or as long as the malfunction is present. STORED CODES Airbag codes are automatically stored in the ORC's memory as soon as the malfunction is detected. A stored code indicates there was an active code present at some time. When a trouble code occurs, the Airbag Warning Indicator illuminates for 12 seconds minimum (even if the problem existed for less than 12 seconds). Once the code is no longer active, the time in minutes it was active, and the number of times the ignition has been cycled since the problem was last detected will be displayed. The minimum time shown for any code will be one minute, even if the code was actually present for less than one minute. Thus, the time shown for a code that was present for two minutes 13 seconds, for example, would be three minutes. If a malfunction is detected a diagnostic trouble code is stored and will remain stored. When and if the malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle count reaches 100 without a reoccurrence of the same malfunction, the diagnostic trouble code is erased and that ignition cycle counter is reset to zero. The ignition cycle counter will be reset and diagnostic trouble code will continue to be a stored code, If the malfunction reoccurs before the count reaches 100. If a malfunction is not active while performing a diagnostic test procedure, the active code diagnostic test will not locate the source of the problem. In this case, the stored code can indicate an area to inspect. Maintain a safe distance from all airbags while performing the following inspection. If no obvious problems are found, erase stored codes, and with the ignition on wiggle the wire harness and connectors, rotate the steering wheel from stop to stop. Recheck for codes periodically as you work through the system. This procedure may uncover a malfunction that is difficult to locate. Audio System Some of the radios are on the PCI Bus system. The PCI Bus inputs into the radio are used for VF dimming, remote steering wheel controls and cabin EQ preference. PCI Bus outputs from the radio are used for the Name Brand Speaker (NBS) relay activation, as well as cabin EQ preference. The radios have the capability of containing multiple vehicle unique equalization curves (cabin EQ preferences) within the radio. These curves will reside in the radio's flash memory. The radio is capable of storing up to 20 unique equalization curves. The latent curves can be selected via the Front Control Module transmitting a PCI Bus message to the radio in response to a radio request for equalization message. Upon receipt of a valid equalization select message response, the radio will switch to output the corresponding equalization curve. All the radios are capable of displaying faults and allowing certain actuation tests through the use of the DRBIII(R). When attempting to perform PCI Bus diagnostics, the first step is to identify the radio in use in the vehicle. When trouble shooting output shorts or 'output' error messages, the following applies: On radios without an external amplifier, the term output refers to the path between the radio and the speaker. This type of circuit can be monitored all the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8733 way through the speaker connections by the radio assembly. When the radio displays a shorted output DTC with this type of system, the speaker, radio, or wiring could be at fault. On radios with an external amplifier, the term 'output' refers to the circuit between the radio connector and the amplifier. The radio is capable of monitoring only this portion and can tell nothing about the circuit between the amplifier and the speakers. Consequently, a shorted output DTC on this type of system would only refer to this circuit. A faulty speaker could not cause this DTC. NAVIGATION RADIO The optional navigation radio system receives GPS signals from up to eight satellites to display the position and direction of the vehicle. Map information is supplied through a DVD-ROM. An electronic gyrosensor and the vehicle's speed sensor enable the system to display the present vehicle position even in locations where GPS signals may be blocked. When a destination is selected, the navigation system uses information from the map to quickly calculate a route. As the vehicle is driven along the chosen route, the operator is guided with pictorial displays and voice prompts. For complete operating instructions, refer to the manual included with the vehicle. REMOTE RADIO CONTROLS These radios can be controlled via remote radio switches (optional). These switches are located on the back side of the steering wheel. They control mode, preset, seek up, seek down, volume up and volume down functions. These functions are inputs to the Body Control Module and can be read with the DRBIII(R) under 'body computer'. The switches are a multiplexed signal to the BCM. The radio control MUX circuit is a 5 volt line that is pulled to ground through different value resistors built into the switches. This causes a voltage drop to be seen by the BCM and it sends a specific message to the radio on the PCI Bus circuit. The radio then responses to the message. This circuit is fairly simple to troubleshoot. The circuit must be complete from the switches in the steering wheel to the BCM. The ground must be complete so that the switches can cause the voltage drop for the BCM to see. The circuit passes through the clockspring so continuity through this devise must be verified. CD CHANGER The new in-dash CD Changer is designed to fit into the existing cubby bin in the center stack. This new cartridge-less CD Changer is controlled by your radio, and allows you to individually load up to four discs at a time. However, due to its compact design, the CD Changer can only carry out one operation at a time. For example, you can not load a new disc while playing another at the same time. Each operation happens sequentially. The radio unit installed with your system provides control over all features of the CD Changer with the exception of the CD load and eject functions, which are controlled by buttons located on the front of the CD Changer. The radio also supplies the power, ground, PCI Bus, left and right speaker output through a single DIN cable. All features you would expect, such as Disc Up/Down, Track Up/ Down, Random and Scan are controlled by the radio, which also displays all relevant CD Changer information on the radio display. The CD Changer contains a Load/Eject button and an indicator light for each of the four disc positions. The individual light indicates whether a CD is currently loaded in that particular chamber of the CD Changer. Pressing the individual Load/Eject button for a particular chamber will eject a disc currently present in that chamber. If the chamber is currently empty, actuating the Load/Eject button will position that chamber to receive and load a new disc in that chamber. DVD/CD CHANGER The DVD/CD Changer (if equipped) is located in the instrument panel below the radio. The DVD/CD Changer can hold one DVD at a time. Three RCA jacks on the front of the unit will allow the use of MP3 players, video systems or camcorders. Body Control Module The body control module (BCM) supplies vehicle occupants with visual and audible information and controls various vehicle functions. To provide and receive information, the module is interfaced to the vehicle's serial bus communications network (PCI). This network consists of the powertrain control module (PCM), the engine control module (ECM) diesel, the mechanical instrument cluster (MIC), the front control module (FCM), the occupant restraint controller (ORC), the occupant classification module (OCM), the overhead console, the ABS module, the hands free module (HFM), the park assist module, the HVAC control module (ATC & MTC), the power sliding door (Left & Right) modules (PSD), the power liftgate module (PLG), the Audio system (which includes the Radio, DVD, CD Changer and Amplifier), the memory seat/mirror/ adjustable pedals module (MSMAPM), the RKE/ Thatcham alarm module (export), the transmission control module (Diesel only) and the sentry key remote entry module (SKREEM). The BCM is operational when battery power is supplied to the module. The body control module provides the following features: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8734 - Power Door Locks - Automatic Door Lock - Door Lock Inhibit - Central Locking (with VTSS Only) - Battery Protection - The BCM will automatically turn off all exterior lamps after 3 minutes and all interior lamps after 15 minutes after the ignition is turned off, if they are not turned off by the driver. - Chime Driver - Compass/Minitrip Support - Interior Lighting (Courtesy/Reading Lamps) - BCM Diagnostic Reporting - Electronic Liftgate Release (with Power Door Locks) - Exterior Lighting - Headlamp Time Delay (with/without Auto headlamps) - Automatic Headlamps (with electrochromatic mirror) - Illuminated Entry - Fade to Off This feature dims the interior lighting (courtesy lamps) gradually if the BCM does not receive any new inputs that would cause the interior lamps to remain on. - PWM Instrument Panel Dimming - Door Lock Inhibit This feature disables the door lock functions if the key is in the ignition and either front door is ajar. Pressing the RKE lock/unlock button under these conditions, result in normal lock/unlock activation. - Power Sliding Door Switch Inputs The BCM has 4 switch inputs for the power sliding door feature: Located in the overhead console are the Left and Right side sliding door switches to activate either or both sliding doors under the proper conditions. Also there are B-Pillar switches located on the Left and Right B-pillar posts. - Power Liftgate Switch Input The BCM has 1 Liftgate switch input located in the overhead console - Power Lockout Switch Input The BCM has 1 Lockout switch that when enabled will disable the B-Pillar sliding door switches from activating either sliding door when depressed. When replacing a body control module there are 2 modules available, a Base and a Midline. The Midline controller is used on vehicles that have Power Door Locks. If a vehicle is equipped with the Vehicle Theft Security System, the midline controller becomes a premium when the theft feature is enabled. NOTE: Do not swap the body control module between vehicles or body control modules off the shelf. Engineering does not recommend that service, dealers or the plant swap Body Control Modules (BCM) between vehicles or off the shelf. The BCM has internal diagnostic capability that assists in diagnosing the system. When an 'open' or a 'Short' circuit exists, the diagnostic tool can be used to read the BCM codes. The codes are very descriptive in identifying the appropriate feature that has faulted. The BCM also learns what features are on the vehicle and if modules are swapped the BCM could set false DTC's based on what it learned. Chime Warning System The BCM monitors the door/liftgate ajar switches, multifunction switches, headlight switch, ignition switch, PCI bus, and the diagnostic tool to perform various chime operations. The BCM uses a low-side driver to control the chime located in the cluster. The chime system provides the Driver with warning chimes for: - Seat belt - Exterior lights on - Key-in Ignition - Key-in Accessory - Engine temperature critical - Low washer fluid - Turn signals on - Dome light on - Low oil pressure - Any warning lamp announcement - High-speed warning Gulf Coast Countries (GCC) only The output sound intensity of the chime is approximately 72 decibels. CHIME PRIORITY Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8735 The following list indicates the priority of the chime when more than one chime is active at the same time: - Seat belt warning - High-speed warning Gulf Coast Countries (GCC) only - Turn signal on - Chime request - Warning lamp announcement The cluster is responsible to set priority on all warning lamp announcement chimes. CHIME ON CONDITIONS The following is a list of the chime warnings and when they will sound. Driver's Seatbelt Unbuckled: Sounds for approximately 6 ± 2 seconds when the ignition is turned on driver's seat belt is not buckled, as a reminder to the driver to buckle the seat belt. Exterior Lights On:Ignition is in the lock position, the driver door is ajar, and the headlight switch is left in any position, other than auto or off.The chime will sound as a warning to the driver until one of the above conditions is removed or until the battery protection time of 3 minutes has expired. Key-In Ignition: Ignition is in the lock position, driver door is ajar and the key is in the ignition. The chime will sound until one of the above conditions is removed or until the battery protection time of 15 minutes has expired. Turn Signal On: When the BCM detects a turn signal input continuously for 1.0 mile/0.6 km and the vehicle speed is greater than 15 mph/24 kph, the chime will sound until the specific turn signal is cancelled. Dome Lights On: Ignition is in the lock position, driver door ajar, and the dome light switch is left in the on position. The chime will sound until one of the above conditions is removed or until the battery protection time of 15 minutes has expired. Low Oil Pressure: The chime will sound when the engine is operating and the oil pressure drops below 4 psi/27.5 kPa. Engine Temperature Critical: The chime will sound when the engine is operating and the coolant temperature exceeds 252° F/122° C or 234° C/112° C(diesel). The chime is continuous at 257° F/ 125° C and will chime for 4 minutes and stop if the temperature drops below 255° F/123° C. Low Washer The chime will sound when the Fluid washer fluid drops below a specific level. Warning Lamp Announcement: A chime will sound to alert the driver to scan the instrument panel and overhead console to see which warning lamp is illuminated. The door/liftgate ajar warning lamp will appear without a chime if the vehicle is running and a door or the liftgate is opened. A chime will sound if the door or liftgate is still open and the vehicle speed is greater than 4 mph/6 kph. High-speed warning Gulf Coast Countries (GCC) only The chime will sound, acting as a warning to the driver that the vehicle speed has exceed 75 mph ± 2/120 kph ± 3. WARNING LAMP ANNOUNCEMENT Low Fuel Lamp: The cluster will request a single chime after the indicator is illuminated. Volt Lamp: The cluster will request a single chime after the indicator is illuminated. Oil Pressure Lamp: The cluster will request a single chime after illuminating the indicator above 450 rpm vehicle operation. Liftgate Ajar Lamp: The BCM determines when to chime for liftgate ajar. Fasten Seat Belt Lamp: The MIC will request a single chime from the BCM when the ignition is turned to the unlock/ run/start positions if the driver seat belt is not buckled and 2 seconds after seatbelt warning chime ends. Check Engine Lamp: The cluster will request a single chime after the indicator is illuminated. Low Washer Fluid Lamp: The cluster will request a single chime after the indicator is illuminated. Engine Temperature Lamp: The cluster will request a single chime when the indicator is first illuminated at 252° F/122° C. OTHER CHIME ON CONDITIONS Programming of an Additional Key Fob: A single cluster chime will sound, which signals that the program mode has been initiated. Programming for Rolling Door Locks: When the programming has been completed, a single tone from the chime system, will occur. Communication Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8736 The Programmable Communication Interface or PCI Bus is a single wire multiplexed network capable of supporting binary encoded messages shared between multiple modules. The PCI bus circuit is identified as D25 and is white with a violet tracer. Additional tracer colors may be added to the violet in order to distinguish between different module connections. The modules are wired in parallel. Connections are made in the harness using splices. The following modules are used on the RS/RG: - Body Control Module - Front Control Module - Occupant Restraint Controller - Occupant Classification Module - Controller Antilock Brake (MK20E) - Antilock Brake Module (MK25E) - Powertrain Control Module (Gas) - Transmission Control Module (Diesel Auto Only) - Engine Control Module (Diesel) - Radio - Amplifier - CD Changer - DVD/CD Changer - Hands Free Module - Automatic Temperature Control Module - A/C Heater Control Module (MTC) - Sentry Key Remote Entry Module (SKREEM) - Memory Seat/Mirror/Adjustable Pedals Module (MSMAPM) - Overhead Console - Mechanical Instrument Cluster - Left Sliding Door Control Module - Right Sliding Door Control Module - Thatcham Alarm Module (Export) - Power Liftgate Module - Park Assist Module Each module provides its own bias and termination in order to transmit and receive messages. The bus voltage is at zero volts when no modules are transmitting and is pulled up to about seven and a half volts when modules are transmitting. The bus messages are transmitted at a rate averaging 10800 bits per second. Since there is only voltage present when the modules transmit and the message length is only about 500 milliseconds, it is ineffective to try and measure the bus activity with a conventional voltmeter. The preferred method is to use the DRBIII(R) lab scope. The 12 v square wave selection on the 20-volt scale provides a good view of the bus activity. Voltage on the bus should pulse between zero and about seven and a half volts. Refer to the following figure for some typical displays. The PCI Bus failure modes are broken down into two categories. Complete PCI Bus Communication Failure and individual module no response. Causes of a complete PCI Bus Communication Failure include a short to ground or battery on the PCI circuit. Individual module no response can be caused by an open PCI circuit at the module, or an open battery or ground circuit to the affected module. Symptoms of a complete PCI Bus Communication Failure would include but are not limited to: - All gauges on the MIC stay at zero - All telltales on MIC illuminate - MIC backlighting at full intensity - Dashed lines in the overhead console ambient temperature display - No response received from any module on the PCI bus (except the PCM/ECM) - No start (if equipped with Sentry Key Immobilizer) Symptoms of Individual module failure could include any one or more of the above. The difference would be that at least one or more modules would respond to the DRBIII(R). Diagnosis starts with symptom identification. If a complete PCI Bus Communication Failure is suspected,suspected, begin by identifying which modules the vehicle is equipped with and then attempt to get a response from the modules with the DRBIII(R) If any modules are responding, the failure is not related to the total bus, but can be caused by one or more modules PCI circuit or power supply and ground circuits. The DRBIII(R) may display BUS ± SIGNAL OPEN or NO RESPONSE to indicate a communication problem. These same messages will be displayed if the vehicle is not equipped with that particular module. The CCD error message is a default message used by the DRBIII(R) and in no way indicates whether or not the PCI bus is operational. The message is only an indication that a module is either not responding or the vehicle is not equipped. NOTE: For 2005 model year, some vehicles will integrate the Transmission Control Module and Powertrain Control Module into a single control module. This new module is the Next Generation Controller for DaimlerChrysler and will be referred to as the Powertrain Control Module (PCM). The Transmission Control Module is part of the Powertrain Control Module. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8737 Diagnostic procedures and DTC numbers are some of the changes you will see which reflect the new combined module technology. The PCM will have four color coded connectors C1 through C4, (C1-BLK, C2-ORANGE, C3-WHITE, C4-GREEN), each PCM connector will have 38 pins each. Two new tools are used for probing and repairing the New PCM connectors. A New tool to release the pins from the PCM connectors Miller #3638 is introduced, you must use the Miller tool #3638 to release the connector pins or harness and connector damage will occur. Also a New tool for probing connectors Miller #8815 is introduced, you must use the Miller tool #8815 to probe the PCM pins or harness and connector damage will occur. There is also a new Verification test and module replacement procedure for the PCM. Door Ajar System The door ajar and liftgate ajar states are used as inputs for the Body Control Module (BCM). The BCM uses these inputs to determine exactly what position the doors and liftgate are in. The DRBIII(R) will display the state of the door ajar and the liftgate ajar switches in Inputs/Outputs. It's important to note, that when any door, or the liftgate is closed, the switch state on the DRBIII(R) will show OPEN. When any door, or the liftgate is open the switch state on the DRBIII(R) will show CLOSED. During diagnosis, if a door or the liftgate is closed and the DRBIII(R) displays the switch state as CLOSED, it indicates a shorted ajar circuit. If the door or the liftgate is open and the DRBIII(R) displays the switch state as OPEN, it indicates an open ajar circuit. Exterior Lighting System HEADLAMP POWER The Headlamp Switch is a direct input to the BCM. The BCM sends a BUS message to the FCM informing it of a headlamp switch status change. The FCM then turns on power to the headlamps through four fuseless circuits. These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied to each filament in a separate circuit. For vehicles equipped with daytime running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination. HEADLAMP SWITCH The Headlamp Switch uses a multiplexed (MUX) circuit to the Body Control Module (BCM). The Headlamp Switch controls the Fog lamp relay, Park lamps and the Low and High headlamps. The BCM then sends a signal through the PCI Bus line to the FCM as to what state the switch has selected. The FCM energizes the high side output drivers to turn ON the desired lamps. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8738 PARK LAMP RELAY The Park Lamp Switch is a direct input to the BCM. The BCM sends a BUS message to the FCM informing it to turn on the park lamp relay. The park lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. FOG LAMP RELAY The Fog Lamp switch is a direct input to the BCM. The BCM sends a BUS message to the FCM informing it to turn on the fog lamp relay. The fog lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Fog lamp functionality is not equipped on all vehicles. The FCM learns that the vehicle is equipped with fog lamps by reading the BCM BUS message. FOG LAMPS The BCM controls the operation of the fog lamp relay that turns the fog lamps ON and OFF. The Fog lamps can only be ON when the park and low beams are ON. If the high beams are switched ON then the Fog lamps will be automatically turned OFF. EXTERIOR LIGHTING BATTERY SAVER The BCM monitors the status of, and controls, the Park Lamps, Headlamps and Fog Lamp relays. If any exterior lamps are left ON after the ignition is turned OFF, the BCM will turn them OFF after 3 minutes. AUTO HEADLAMPS This feature is available on vehicles equipped with both the Electrocromatic Mirror (ECM) and the Compass/Mini-Trip Computer (CMTC). When the BCM detects a day/night signal from the CMTC, an ECM is present and Auto Headlamp mode is selected. Front Control Module The Front Control Module (FCM) is an electrical control and interface center located in the engine compartment. When it is mated to the Power Distribution Center (PDC), it is referred to as the Integrated Power Module (IPM). The IPM, with its fuses and relays provides power and signal distribution throughout most of the vehicle. The FCM receives both hard wire and digital electronic inputs from the vehicle electrical system through the PDC. Based on these inputs and the ignition switch position, it provides direct power feeds and relay control to some of the vehicles most critical electrical systems. The Front Control Module provides the following features: Controlled power feeds: - Front airbag system - Headlamp power - EATX module power (4 speed only) - Front washer motor - Rear washer motor - Cabin Heater - Brake shift interlock system Relay controls: - Fog lamp relay (when equipped) - Park lamp relay - Front wiper on relay - Front wiper high/low relay - Accessory relay - Horn relay - Front & rear blower relay - Name brand speakers (NBS) relay - Adjustable pedals relay (non-memory) - Electronic back light (EBL) run only relay Electrical inputs: - Headlamp battery supplies 1 & 2 - Module battery supply - Power ground - Ignition switch RUN or START position status - Ignition switch START only status - PCI Bus - Stop lamp switch - Horn switch - Back-up switch - Wiper park switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8739 - Washer fluid level switch - Brake fluid level switch - Ambient temperature sensor - Right park lamp outage - Left park lamp outage - Battery IOD - Battery (+) connection detection - Flash reprogramming voltage CONTROLLED POWER FEEDS Front airbag system The FCM provides power to the Occupant Restraint Control (ORC) system through two fuseless circuits (ORC RUN/START, and ORC RUN only). These circuits are electronically controlled and continuously monitored for malfunctions. Power is supplied while the ignition switch is in the RUN and START positions on pin 48 of the FCM connector, and in the RUN only position on pin 29. Headlamp power The headlamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a headlamp switch status change. The FCM then turns on power to the headlamps through four fuseless circuits. These circuits are electronically controlled and continuously monitored for malfunctions.Power is supplied to each filament in a separate circuit. For vehicles equipped with Daytime Running Lamps (DRL), the FCM electronically steps down the headlamp voltage to provide the desired illumination. EATX power The electronic automatic 4 speed transmission module is powered when the ignition switch is in the UNLOCK, RUN or START positions. This circuit is electronically controlled and continuously monitored for malfunctions. Power is supplied through pin 27 of the FCM connector. Front washer motor The front washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The front washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition, the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Rear washer motor The rear washer switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it of a request to wash. The rear washer motor is then powered through low side control inside the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. In addition,the FCM electronically protects the washer motor from system voltages higher than 16 volts by automatically switching off the low side circuit. Cabin Heater When the ignition is in Run, the FCM monitors the PCI bus for the Cabin Heater Activation request. The Automatic or Manual Temperature Control initiates this request only when all conditions for the Cabin Heater activation are favorable. The request carries the status bit that the FCM requires to activate its Cabin Heater Assist Control output. This output is a low side driver (coming from FCM pin 15) which supplies a ground signal to the Cabin Heater (pin 5). When the Cabin Heater receives this ground signal input, it interprets this as an activation signal. The FCM low side driver is also capable of diagnostic sensing. The driver will sense an open circuit when the driver is off, and will sense a short to voltage when the driver is on. The FCM will set DTC's for both of these types of faults. For additional information, refer to Cabin Heater under General Information and Diagnostic Procedures in the manual. Brake shift interlock system The brake shift interlock solenoid receives power from both high side and low side controls inside the FCM. The high side control is on the same circuit as the EATX module power, and the low side control comes through pin 47 of the FCM connector. The solenoid is controlled by the low side driver when the brake pedal is pressed. Both circuits are continuously monitored for malfunctions. RELAY CONTROLS Fog lamp relay The fog lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the fog lamp relay. The fog lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Fog lamp functionality is not equipped on all vehicles. The FCM learns that the vehicle is equipped with fog lamps by reading the BCM PCI Bus message. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8740 Park lamp relay The park lamp switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the park lamp relay. The park lamp relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper on relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper on relay. The front wiper on relay is then powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Front wiper high/low relay The front wiper switch is a direct input to the BCM. The BCM sends a PCI Bus message to the FCM informing it to turn on the front wiper high/ low relay. The relay switches power between the low speed and high speed windings of the wiper motor. The front wiper high/low relay is powered through low side control of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Accessory relay The accessory relay works in conjunction with the FCM's power accessory delay feature to control the operation of the radio, power windows, washer motors,wiper motors and power outlet. The accessory relay is turned on through low side control on pin 35 of the FCM. This circuit is electronically controlled and continuously monitored for malfunctions. Depending on the ignition switch position, the accessory relay will remain on or will time-out and turn off. The accessory relay remains on in the RUN and ACCY positions of the ignition switch. In the UNLK and OFF positions, the relay will remain energized for 45 seconds then turn off. During this time-out period, if the driver or passenger doors are opened, the relay will turn off immediately. While the ignition switch is in the START position, the relay will also drop-out, then resume operation. Accessory relay operation is most noticeable by observing the operation of the radio or blower functions. Horn relay The horn relay operates through a direct wire input to the FCM from the horn switch (FCM pin 17) , or a PCI Bus message from the BCM. The relay responds to the horn switch, remote door lock and VTA alarm functions. The horn relay is powered through low side control on pin 10 of the FCM. Under normal operating conditions, if the horn is pressed for longer than 30 seconds, the FCM will automatically deactivate the horn to prevent damage to it. The FCM will re-activate control of the relay after a 25 second cool-down period. This circuit is electronically controlled and continuously monitored for malfunctions. Front and rear blower relay RS with MTC Upon ignition on, the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus.The front blower relay and the rear blower relay, if equipped, are then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. RG with MTC Upon power up (Power switch on), the A/C-Heater Control Module sends a blower relay on request to the FCM over the PCI Bus. The front blower relay is then powered through low side control through FCM pin 30. The relay provides the high side to the blower motor, and the blower speed is governed through low side control in the A/C-Heater Control Module. This circuit is electronically controlled and continuously monitored for malfunctions. Name Brand Speakers (NBS) relay The NBS relay operates through the vehicle bus interface between the radio and the FCM. When the radio is turned on, the radio sends a PCI Bus message to the FCM. The NBS relay is then powered on through low side control on pin 11 of the FCM. The relay supplies power to the amplified speaker, and ground is supplied through the radio. This circuit is electronically controlled and continuously monitored for malfunctions. Electronic Back Light (EBL) relay The rear defrost switch is part of the Automatic Temperature Control or A/C-Heater Control Module (Manual Temp). When the ignition switch is in the RUN position and the rear defrost switch is turned on, the ATC or A/C-Heater Control Module sends a PCI Bus message to the FCM. The EBL run only relay is then powered through low side control on pin 31 of the FCM. The relay provides the high side to the rear window defrost grid, and ground is attached to the vehicle body. The FCM will only allow the rear defrost to operate in the RUN position. This circuit is electronically controlled and continuously monitored for malfunctions. Adjustable Pedals Relay (Non-Memory) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8741 The Adjustable Pedals Relay is only on nonmemory Adjustable Pedals System equipped vehicles. The relay is supplied battery voltage from the IPM and is electronically controlled with a low side driver within the FCM. The relay is energized when the transmission is in reverse and when cruise control operation is engaged. This action disables the Adjustable Pedals System from movement. This circuit is continuously monitored for proper function. ELECTRICAL INPUTS Headlamp battery supplies 1 & 2 - 12 volt input on pins 1 and 2. Battery supply voltage for switching headlamp circuits only. Module battery supply - 12 volt input on pin 9. Battery supply voltage for all other FCM operations. Power ground - Ground source on pin 8 for all FCM operations. Ignition switch RUN or START position status - 12 volt input on pin 37. Allows the FCM to determine the ignition switch status for related FCM operations. PCI Bus - Approximately 7.5 volt input on pin 22. Allows the FCM to communicate with other modules on the vehicle bus. Stop lamp Switch status - 12 volt input on pin 44. Provides for brake shift interlock function. Horn Switch - Ground input on pin 17. Primary means for engaging the horn. Back-up switch - Ground input on pin 39. Input is converted to a PCI Bus status message for use by other modules. Wiper park switch - Ground input on pin 16. Used to determine park placement of wipers. Also used as feedback to FCM to determine correct operating mode of wipers. Washer fluid level switch - Ground input to pull-up on pin 18. Ground is switched into the circuit when washer bottle fluid level is low. Brake fluid level switch - Ground input to pull-up on pin 36. Ground is switched into the circuit when brake fluid level is low. Ambient temperature sensor - Resistive input to pull-up on pin 25. Corresponding voltage level is converted to a PCI Bus message for use by other modules on the bus. Right park lamp outage - 12 volt input on pin 21. Used to determine if right park lamp circuit is operating properly. Left park lamp outage - 12 volt input on pin 41. Used to determine if left park lamp circuit is operating properly. Battery IOD - 12 volt input on pin 20. The FCM enters a low power consumption mode when the ignition is turned OFF. This low current draw battery supply keeps the microprocessor functioning in the low power mode. Battery (+) connection detection - 12 volt input on pin 38. The battery connection on the PDC incorporates the use of an internal switch to determine if the connector is properly mated and the Connector Positive Assurance (CPA) is engaged. If the CPA is not properly engaged, a voltage on pin 38 will be interpreted as an unseated connector and a fault will set. Flash programming voltage - 20 volt input on pin 42. When a DRBIII(R) is connected and the proper flash reprogramming sequence is selected, the 20 volt signal will be applied through pin 42. Heating and A/C System AUTOMATIC TEMPERATURE CONTROL (ATC) MODULE USAGE CAUTION: Do not swap ATC Modules from vehicle to vehicle. Software versions differ between models and between model years. Installing a ATC Module with software that is incompatible for a given vehicle can result in either improper or failed HVAC system operation. SYSTEM AVAILABILITY - The ATC system is a Three-Zone Air Conditioning System. SYSTEM CONTROLS The ATC Module: - is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - provides an A/C request over the PCI Bus to the Powertrain Control Module (PCM) when compressor operation is desired. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8742 - for exports with diesel engines, provides a Cabin Heater activation request over the PCI Bus to the Front Control Module (FCM) when conditions are favorable for Cabin Heater operation. - uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - uses input from infrared (I/R) sensors, which measure surface temperature, to maintain occupant comfort levels. The I/R sensors are mounted in the instrument panel center bezel. - can be operated in a manual mode. - provides a blower relay on request over the PCI Bus to the Front Control Module (FCM) when blower operation is desired. - controls front blower operating speed, providing 10 speeds in manual mode and infinite speeds in automatic mode. - provides a cold engine blower lockout function. A Blower Speed Clamping feature minimizes occupant discomfort by controlling the amount of warm air coming out of the HVAC system should the Powertrain Control Module (PCM) disable A/C Compressor operation while the Automatic Temperature Control (ATC) is set in an automatic mode. The PCM disables the A/C compressor if the A/C pressure is too low, if the A/C pressure is too high, if engine overheating is immanent, or if an engine overheating condition exists. The ATC clamps the blower speed if the outside air temperature is greater than 50° F (10° C) and the PCM has disabled the A/C compressor. This means that the ATC will not adjust blower speed automatically when the clamping feature is enabled, e.g. if the clamping feature is enabled while in Auto Lo the blower will continue to run in low speed; if the clamping feature is enabled while in Auto Lo and the operator selects Auto Hi the blower will continue to run in low speed; if the clamping feature is enabled while in Auto Hi the blower will continue to run at the highest speed. In any case the operator can manually change the blower speed as desired. When diagnosing blower related symptoms verify that none of the above conditions for disabling the A/C compressor exist before diagnosing the blower circuits and components. - controls rear blower operating speed, providing 10 speeds in manual mode and infinite speeds in automatic mode. The separate front and rear Blower Motor Controllers operate as follows: When blower operation is desired, the Blower Motor Controller provides a 10.0 volt signal to the ATC Module over a control circuit. The ATC Module provides a variable duty cycle ground to the 10.0 volt signal based on input from the blower switch. When the blower switch is set to LO speed, the ATC Module provides a short duty cycle (less time grounding the signal voltage). As higher blower speeds are requested, the ATC Module increases the duty cycle (more time grounding the signal voltage). When the blower switch reaches HI speed, the duty cycle increases to where the signal pattern is almost a flat line (with brief voltage spikes). - controls the front and rear electric door actuators operation. A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The ATC Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the ATC Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. - activates and deactivates the Rear ATC Switch. The Rear ATC Switch (Three-Zone Only): - provides desired rear blower speed input to the ATC Module. - provides desired rear blend and mode door position input to the ATC Module. The Dual-Zone ATC system uses: - two front, two-wire electric blend door actuators. - one front, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. The Three-Zone ATC system uses: - two front, two-wire electric blend door actuators. - one front, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. - one rear, two-wire electric blend door actuator. - one rear, two-wire electric mode door actuator. System Relays: - The Integrated Power Module (IPM) houses and provides power to the A/C Clutch Relay, Front Blower Motor Relay, and Rear Blower Motor Relay. SYSTEM REVISIONS The 2005 ATC system remains mostly carryover from 2004. Revisions to the 2005 ATC system include: - all new version 0012 software. SYSTEM DIAGNOSTICS Fault detection is through active and stored Diagnostic Trouble Codes (DTC's) - DTC's are displayed the DRBIII(R). - Active DTC's are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTC's are those which occurred in the system since the ATC Module received the last "clear diagnostic info" message. The AC Cooldown Test: - is actuated with the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8743 - checks A/C system performance based on evaporator temperature sensor input. WARNING: DO NOT OPERATE THE DCHA IN AN ENCLOSED AREA SUCH AS A GARAGE THAT DOES NOT HAVE EXHAUST VENTILATION FACILITIES. ALWAYS VENT THE DCHA's EXHAUST WHEN OPERATING THE DCHA. REFER TO VENTING THE DCHA's EXHAUST UNDER CABIN HEATER IN THE GENERAL INFORMATION PORTION OF THIS SECTION FOR PROPER EXHAUST VENTING INSTRUCTIONS. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. CAUTION: Do not activate the A/C Cooldown Test with the engine off. Failure to follow these instructions can result in internal damage to the DCHA Heater Module. - The FCM monitors the PCI bus for the Cabin Heater Activation request. The request carries the status bit that the FCM requires to activate it's Cabin Heater Assist Control output. This output is a low side driver (coming from FCM pin 15) which supplies a ground signal to the Cabin Heater (pin 5). When the Cabin Heater receives this ground signal input, it interprets this as an activation signal. - The FCM low side driver is also capable of diagnostic sensing. The driver will sense an open circuit when the driver is off, and will sense a short to voltage when the driver is on. The FCM will set DTC's for both of these types of faults. For additional information, refer to Cabin Heater under General Information and Diagnostic Procedures. - will not run the air conditioning portion of this test if ambient temperature is below 12° C (53° F). The forced Cabin Heater activation will occur even if the air conditioning portion of this test fails to initiate because AC Cooldown test criteria was not met. When activated, the DCHA will operate for approximately seven minutes. Three minutes to run and four minutes to purge. - will pass the air conditioning portion of this test if the evaporator temperature drops 6.7° C (20° F) within two minutes of starting this test. - messages (air conditioning related only) display on the DRBIII(R) after running this test. These messages will clear after paging back out of this test. Therefore, it is important to note all of the AC Cooldown test messages before doing so. - All Cabin Heater-related DTC's display under Cabin Heater, Read DTC's. - will cause the DELAY and Snowflake VF segments on the ATC to flash for 162 seconds (RG with DCHA only). If the air conditioning portion of this test fails, the DELAY and Snowflake VF segments will continue to flash until the vehicle is driven more than three miles. MANUAL TEMPERATURE CONTROL (MTC) Vehicle Compatibility For MTC Modules MODULE USAGE SYSTEM AVAILABILITY - Three different types of systems are currently available for these vehicles. Single-Zone Air Conditioning System - Dual-Zone Air Conditioning System - Three-Zone Air Conditioning System Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8744 SYSTEM CONTROLS The A/C-Heater Control Module: - is fully addressable with the DRBIII(R). - communicates over the Programmable Communication Interface Multiplex System (PCI) Bus. - provides an A/C request to the Powertrain Control Module (PCM) over the PCI Bus when compressor operation is desired. - uses input from the evaporator temperature sensor to prevent evaporator freeze up while maintaining optimum cooling performance. - for exports with diesel engines, provides a Cabin Heater activation request to the Front Control Module (FCM) over the PCI Bus when conditions are favorable for Cabin Heater operation. - for RS vehicles, provides a blower relay on request to the FCM over the PCI Bus upon ignition on. - for RG vehicles, provides a blower relay on request to the FCM over the PCI Bus when the Power switch on the A/C-Heater Control Module is turned on. - controls front blower operating speed. For RS vehicles, the four speed settings are Low, M1, M2, and High. For RG vehicles the five speed settings are Low, M1, M2, M3, and High. - for RS vehicles uses the blower switch to control system on/off and blower speed. - for RS vehicles uses the rear wiper/washer switch to control rear wiper/washer operation. - for RS vehicles, provides a rear wiper on request to the Body Control Module (BCM) when rear wiper operation is desired. - for RS vehicles, provides a rear washer on request to the Body Control Module (BCM) when rear washer operation is desired. - controls EBL operation. - on three-zone systems, activates and deactivates the Rear A/C-Heater Control. - on three-zone systems, controls rear blower operating speed. The three speed settings are Low, Med, and High. - controls the front and the three-zone system rear electric door actuators operation. A simplified control system for operation of the mode, recirculation, and temperature control actuators provides positive positioning without the complexity of feedback from position sensors. The A/C - Heater Control Module knows the number of operating actuator revolutions required for full door travel as well as the number of actuator commutator pulses per revolution. Using these parameters, the A/C - Heater Control Module runs the actuator for the number of commutator pulses that correspond to the desired door position. To maintain accuracy, the system recalibrates itself periodically at known zero and full travel conditions. On Three-Zone systems, the Rear A/C-Heater Control: - controls rear blower motor operating speed. The three blower speeds are Low, Med, and High. - provides desired rear blend and mode door position input to the A/C-Heater Control Module. The Single-Zone HVAC system uses: - one, two-wire electric blend door actuator. - one, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. The Dual-Zone HVAC system uses: - two, two-wire electric blend door actuators. - one, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. The Three-Zone HVAC system uses: - two front, two-wire electric blend door actuators. - one front, two-wire electric mode door actuator. - one, two-wire electric recirculation door actuator. - one rear, two-wire electric blend door actuator. - one rear, two-wire electric mode door actuator. System Relays: - The Integrated Power Module (IPM) houses and provides power to the A/C Clutch Relay, Front Blower Motor Relay, and Rear Blower Motor Relay. SYSTEM REVISIONS The 2005 MTC system remains mostly carryover from 2004. Revisions to the 2005 MTC system include: SYSTEM DIAGNOSTICS Fault detection is through active and stored Diagnostic Trouble Codes (DTC's) - DTC's are displayed by the DRBIII(R). - Active DTC's are those which currently exist in the system. The condition causing the fault must be repaired in order to clear this type of DTC. - Stored DTC's are those which occurred in the system since the A/C-Heater Control Module received the last "clear diagnostic info" message. The A/C Cooldown Test: - is actuated with the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8745 - checks A/C system performance based on evaporator temperature sensor input. - will not run if ambient temperature is below 12.7° C (55° F). - will pass if the evaporator temperature drops 6.7° C (20° F) within two minutes of starting the test. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - for RS vehicles will cause the Rear Wipe/Wash and A/C status indicators on the A/C-Heater Control Module to flash alternately while the test is running. - for RG vehicles will cause the PWR and A/C status indicators on the A/C - Heater Control Module to flash alternately while the test is running. The A/C status indicator will flash twice per second to indicate that the A/C Cooldown Test needs to be run. The A/C status indicator will stop flashing twice per second if either the A/C Cooldown Test returns passed, or if any button on the control is pressed, or if the ignition is cycled and the odometer shows greater than eight miles. The HVAC Door Recalibration function: - is actuated with the DRBIII(R) After completing HVAC Door Recalibration, the DRBIII(R) will the store the total span and the status of each door actuator. Selecting HVAC Door Cal Monitor in the System Tests will display this information. - homes and repositions door actuators. - monitors for door span faults on the actuator circuits. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. - for RS vehicles will cause the Rear Wipe/Wash and RECIRC status indicators on the A/C-Heater Control Module to flash alternately while the test is running. - for RG vehicles will cause the PWR and RECIRC status indicators on the A/C - Heater Control Module to flash alternately while the test is running. The RECIRC status indicator will flash twice per second to indicate that the HVAC Door Recalibration Test needs to be run. The RECIRC status indicator will stop flashing twice per second if either the HVAC Door Recalibration Test returns passed, or if any button on the control is pressed, or if the ignition is cycled and the odometer shows greater than eight miles. The Actuator Circuit Test: - is actuated with the DRBIII(R). - monitors for shorted actuator circuits. - allows service to easily diagnose and troubleshoot up to three simultaneous shorts. - supplements the continuous diagnostics on the actuator drive system. - faults display on the DRBIII(R) as test messages only after running the test. - faults will not display on the DRBIII(R) as Diagnostic Trouble Codes. When Performing the Actuator Circuit Test CAUTION: - Shorted rear door driver circuits can cause additional Actuator Circuit Test messages to set for circuits where no condition exists to cause a fault. - To ensure a proper diagnosis, repair all Short Too Complex messages first, all rear door driver circuit related messages second, all common door driver circuit related messages third, and all front door driver circuit related messages last. - The DRBIII(R) can display up to three Actuator Circuit Test messages at a time. After repairing each Actuator Circuit Test message, cycle the ignition switch, then rerun the Actuator Circuit Test to ensure no new messages exist. - The Short Too Complex message: indicates that a specific determination of which lines are shorted could not be made. - is caused by more than three drivers being shorted in the same direction. For example, four drivers all shorted to ground, or two or more drivers shorted with at least one driver shorted to ignition/battery and one driver shorted to ground. - Messages displaying: XXX Driver/Circuit Shorted to Ignition/ Battery will set on a per-driver basis. - XXX Driver/Circuit Shorted to Ground will set on a per-driver basis. - the same two drivers/circuits shorted to ignition/battery as-well-as shorted to ground indicates that two actuator driver circuits are shorted together.When the test returns passed, then troubleshooting should proceed to clearing faults and running the HVAC Door Recalibration system test as a final check of system health. Instrument Cluster The Instrument Cluster receives and sends messages to other modules via the PCI bus circuit. The indicator lamps will illuminate briefly for a bulb check when the ignition is turned from off to run. All of the gauges receive their information via the PCI bus from the powertrain control module and body control module. The gauges and the LEDs are not individually replaceable thereby requiring complete replacement of the Instrument Cluster if a repair is necessary. In the event that the Instrument Cluster loses communication with other modules on the PCI bus, the cluster will display no bus in the VF display. The Trip/Reset button is used to switch the display from trip to total mileage. Holding the button when the display is in the trip mode will reset the trip Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8746 mileage. This button is also used to put the cluster into self-diagnostic mode. The odometer display uses blue-green vacuum fluorescent digital characters. On base models, the Instrument Cluster has three gauges: Speedometer, fuel and temperature.A red dot appears through openings in the Instrument Cluster face (P-R-N-D-2-1) to indicate the gear selected. With other models, the Instrument Cluster may also include a tachometer and use a vacuum fluorescent shift indicator. The high-line Instrument Cluster features Electroluminescent Illumination of the gauge faces (EL Panel). This feature eliminates the use of bulbs for ,gauge/panel lighting. In a manner similar to fluorescent lights, a/c voltage from an inverter integrated circuit chip is applied to the phosphorescent material, causing it to glow. The phosphorescent material is screen-printed onto flexible Mylar sheets that form the gauge faces. The odometer display and door/liftgate ajar indicators turn on when a door is opened to assist both the customer and service technician to view the odometer without turning the ignition on. On models with AutoStick, the display includes an O/D OFF indicator that is illuminated when the driver presses the Overdrive Off button on the transaxle shifter. INSTRUMENT CLUSTER SELF TEST 1. Depress and hold the Odometer Reset button. 2. Turn the ignition switch to on. 3. Release the Odometer reset button. The Instrument Cluster will illuminate all indicators and step the gauges through several calibration points.Also, the odometer will display any stored codes that may have set. Interior Lighting COURTESY LAMP CONTROL The body controller has direct control over all of the vehicle's courtesy lamps. The body computer will illuminate the courtesy lamps under any of the following conditions: 1. Any door ajar and courtesy lamp switch on the headlamp switch is not in the dome off position. 2. The courtesy lamp switch on the headlamp switch is in the dome on position. 3. A Remote Keyless Entry unlock message is received. 4. Driver door unlocked with key (with VTSS only). ILLUMINATED ENTRY Illuminated entry will be initiated when the customer enters the vehicle by unlocking the doors with the key fob, or with the key if the vehicle is equipped with vehicle theft alarm. Upon exiting the vehicle, if the lock button is pressed with a door open, illuminated entry will cancel when the door closes. If the doors are closed and the ignition switch is turned on, the illuminated entry also cancels. The illuminated entry feature will not operate if the courtesy lamp switch is in the dome off position. INTERIOR LIGHTING BATTERY SAVER If any of the interior lamps are left on after the ignition is turned off, the BCM will turn them off after 8 minutes. To return to normal operation, the courtesy lamps will operate after the dome lamp switch or door ajar switch changes state. The glove box and switched reading lamps require that the ignition be turned to the on/acc position. Memory System The memory system consists of power driver's seat, power mirror, adjustable pedals and radio presets. The Memory Seat/Mirror/Adjustable Pedals Module (MSMAPM) is located under the driver's seat. It receives input from the following: driver's manual 8-way seat switch, driver's seat position sensors, PCI bus circuits, and the power mirror sensors. The module uses these inputs to perform the following functions: position the driver's memory seat, both exterior mirrors (during recalls), both pedals, and send/receive the memory system information over the PCI bus. The Memory Set Switch is wired to the Body Control Module (BCM). A button (either #1 or #2) pressed on the set switch causes the BCM to send a message to the MSMAPM which in turn will send a motion status message back to the BCM. If the message from the MSMAPM indicates no current motion, the BCM will send a recal message to the module. The MSMAPM will set the seat, exterior mirror, pedals, and radio to the presets for the indicated driver. If any one of the memory controlled systems is inoperative from its manual switch, use the schematics and diagnostic information to correct the concern. This manual addresses the memory problems only and it is assumed there is not a basic component failure. POWER SEAT The memory power seat provides the driver with 2 position settings for the driver's seat. Each power seat motor is connected to the MSMAPM with two motor drive circuits. Each circuit is switched between battery and ground. By being able to bidirectionally drive the circuits, the MSMAPM controls the Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8747 movement of the motors based on input from the power seat switch or from the position sensors when performing a memory recall. Each motor contains a potentiometer to monitor the seat position. To monitor the position of the motor, the MSMAPM sends out a 5-volt reference on the sensor supply circuit.The sensor is grounded back to the module on a common ground circuit. Based on the position of the sensor, the MSMAPM monitors the voltage change through the sensor on a separate signal circuit. The MSMAPM stores the input value of each of the four seat potentiometers in memory when the system requests a set. The driver can initiate a memory recall, using either the door mounted memory switch or the RKE transmitter (if the remote linked to memory feature is enabled via the EVIC). When initiated, the MSMAPM adjusts the four seat sensors (by using the motors) to match the memorized seat position data. For safety, the memory seat recall is disabled by the MSMAPM when the vehicle is out of park position or if the speed is not zero. Any obstruction to seat movement over a 2-second delay will cause the seat to stop moving in which case a stalled motor would be detected by the MSMAPM and the corresponding seat output would be deactivated. However, if the object obstructing the seat is removed, the seat will function normally again. MEMORY MIRROR The driver side view mirror contains vertical and horizontal bi-directional drive positioning motors and position sensors. The MSMAPM provides a 5-volt reference on the signal circuit to each position sensor. The sensors share a common ground circuit. The MSMAPM monitors the position of the mirror motors by measuring the voltage on each signal circuit. When a memory position is set, the MSMAPM monitors and stores the position of the outside mirror. The MSMAPM adjusts the mirror to the appropriate positions when a memory recall message is received from the RKE or is requested from the memory set switch. The power mirror switch during non-memory operation operates the mirror independently of the MSMAPM. Overhead Console COMPASS/TEMPERATURE MODULE, COMPASS/MINI-TRIP COMPUTER or ELECTRONIC VEHICLE INFORMATION CENTER The Compass/Temperature Module (CT), Compass/Mini-Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) is located in the overhead console. The CT provides the vehicle operator with only outdoor temperature and the compass heading. The CMTC or EVIC supplements the standard vehicle instrumentation. The CMTC and EVIC use a vacuum fluorescent (VF) display to supply the vehicle operator with a compass heading, outdoor temperature, average fuel economy, distance to empty, trip odometer, elapsed ignition on time, distance to service, warning messages, and service messages. The difference between a CMTC and an EVIC is that only the EVIC provides additional memory, feature programming, and warning messages. The EVIC is capable of displaying warning messages and memory system messages when the vehicle is equipped with memory systems. The EVIC also provides the interface to enable and disable vehicle programmable features when the vehicle is equipped with certain features. If equipped, the EVIC is also available with an integrated Universal Garage Door Opener (UGDO) known as HomeLink(R). The EVIC may also be equipped with up to 4 power door switches: ON/ OFF, Left Sliding Door, Right Sliding Door, and Liftgate. The CT function buttons are labeled C/T and US/M. The CMTC function buttons are labeled US/M, C/T, RESET, and STEP. The EVIC function buttons are labeled C/T, RESET, STEP, and MENU. The three UGDO buttons are labeled with dots to indicate the channel number. The BCM supplies most of the information displayed by the CMTC/EVIC. Display information, except for the internal compass function, is received over the PCI bus. The FCM supplies the ambient temperature sensor information via the PCI bus. The CMTC/EVIC sends and receives data over the PCI bus, communicating with the BCM, PCM, FCM, and the Instrument Cluster. Tire Pressure Monitoring System information is received from the SKREEM via PCI bus information. The tire pressure sensors are mounted to the vehicle wheels. For complete information, refer to the Tire Pressure Monitoring System section. VEHICLE INFORMATION DISPLAY The CMTC/EVIC provides the following functions: - Compass direction - Outside temperature - Elapsed ignition on time - Distance to empty - Average fuel economy - Trip odometer - Distance to service The EVIC will also display the following driver alert messages: - TURN SIGNAL ON (with vehicle graphic) - PERFORM SERVICE - DOOR OPEN (individual or multiple doors, with graphic) - LOW TIRE PRESSURE (when equipped) - ADJUSTABLE PEDAL DISABLED CRUISE ENGAGED (when equipped) - ADJUSTABLE PEDAL DISABLED VEHICLE IN REVERSE (when equipped) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8748 An audible chime or chimes will accompany any displayed warning messages. Chime requests with an OPEN message are dependent upon vehicle speed. The CT/CMTC/EVIC will not display information for any of the screens for which it did not receive the proper PCI bus data. Refer to the symptom list in the Overhead Console section for problems related to the CT/CMTC/EVIC. The CMTC/EVIC receives the following messages from the Body Control Module (BCM): - Verification of US/Metric status - VF display dimming brightness and exterior lamp status - Elapsed Ignition On Time data - Average Fuel Economy - Distance to Empty - Distance to service - Driver warning messages The CT/CMTC/EVIC receives the following messages from the Front Control Module (FCM): - Outside Temperature The CMTC/EVIC receives the following messages from the Powertrain Control Module (PCM): - Trip Odometer data - Vehicle Speed The EVIC receives the following messages from the Adjustable Pedal System Module (APS): - APS status warnings The CT/CMTC/EVIC receives the following messages from the Sentry Key Remote Electronic Entry Module (SKREEM): - Tire Pressure information The CMTC/EVIC transmits the following messages to the BCM: - Status Request: Beep, Reset, US/M Toggle - Current Display STEP BUTTON The STEP Button can be used in one of the following three ways: 1. To sequentially select one of seven displays or blank display in the following order: - Average Fuel Economy - Distance to Empty - Trip Odometer - Time Elapsed - Distance to Service Message - Off (Blank) 2. To set the magnetic variance zone when VARIANCE = X (X = 1 - 15) is indicated in the VF Display. 3. To select the displayed programmable feature setting. (When equipped.) MENU BUTTON (EVIC only) For complete information of the programmable features and memory messages. Use the MENU button to sequentially step the EVIC through the programmable features. MENU BUTTON (EVIC only) For complete information of the programmable features and memory messages.Use the MENU button to sequentially step the EVIC through the programmable features. RESET BUTTON The RESET Button has two different functions: 1. To clear the trip functions that may be reset 2. To enter and exit the diagnostic mode Pressing the RESET button once will clear the trip function that is currently being displayed (except Distance to Service) and the CMTC/EVIC will send a PCI bus beep request to the BCM. If the RESET button is pressed again within 3 seconds, the CMTC/EVIC will reset ALL of the trip functions and an additional beep request is sent to the BCM. The trip functions that may be reset are: - Average Fuel Economy - Trip Odometer - Elapsed Time Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8749 A reset will only occur if one of the trip functions that may be reset is currently being displayed. Pressing the RESET button for more than three (3) seconds resets the Distance to Service function while the Distance to Service message is being displayed. The CMTC/EVIC module will send a beep request to the BCM. Simultaneously pressing the RESET button and the STEP button while turning the ignition from Off to On will enter the CMTC/EVIC into the self-diagnostic mode. COMPASS/TEMPERATURE (C/T) BUTTON Actuating the Compass/Temperature Button (C/T) will cause the CMTC/EVIC to display the compass and temperature information. This function will operate from another traveler display or from the programmable feature mode. TRAVELER DISPLAY FUNCTIONS Using the STEP button will change the CMTC/ EVIC between modes of operation and display the appropriate information according to data received from the PCI Bus. COMPASS/TEMPERATURE The CMTC/EVIC simultaneously displays the compass reading and the outside temperature. Outside temperature information is received via the PCI bus from the FCM. The CMTC/EVIC module internally senses and calculates the compass direction. COMPASS OPERATION - ALL Upon ignition on, if the calibration information stored in the CMTC memory is within the normal range, the CMTC will perform in slow Auto-Cal mode. In slow Auto-Cal mode, the CMTC continuously compensates for the slowly changing magnetic field of the vehicle. The compass module detects changes in the vehicle magnetism and makes appropriate internal corrections to ensure proper displayed direction. However, if the calibration information stored in the CMTC memory is not within the normal range at ignition on, the CMTC will enter fast Auto-Cal. CAL is displayed along with the temperature. Auto activation of the fast Auto-Cal mode will also occur when the CMTC is subjected to high magnetic field strength levels, which cause all compass readings to be erroneous for a continuous period of five (5) minutes. During fast Auto-Cal, CAL will be displayed along with the temperature. Fast Auto-Cal can also be performed manually, by pressing and holding the RESET button for 10 seconds during the Compass/Temperature display mode. SETTING MAGNETIC ZONE VARIANCE Variance is the difference between magnetic North and geographic North. For proper compass function, the correct variance zone must be set. Refer to the Zone Variance map for the correct zone. Follow these steps to check or change the variance zone: CMTC/EVIC: - The ignition switch must be in the On position and the CMTC/EVIC display must not be blank. - If the compass/temperature data is not currently being displayed, momentarily press and release the C/T button to display compass/temp information. - Press and hold the RESET button (approximately 5 seconds) until VARIANCE = XX is displayed. The CMTC/EVIC will display the variance zone stored in memory and the word VARIANCE. - Use the RESET button to select the proper variance zone number, 1 through 15. - After selecting the proper zone number, momentarily press and release the RESET button. The variance zone is then stored in the memory and the CMTC/EVIC returns to normal operation. CT: - The ignition switch must be in the On position and the C/T display must not be blank. Press and hold the C/T and US/M buttons (approximately 5 seconds) until VARIANCE = XX is displayed. The C/T will display the variance zone stored in memory and the word VARIANCE. - Use the US/M button to select the proper variance zone number, 1 through 15. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8750 - After selecting the proper zone number, momentarily press and release the C/T button. The variance zone is then stored in the memory and the C/T returns to normal operation. COMPASS CALIBRATION The compass module has 2 types of auto calibration; slow-cal and fast-cal. Slow-cal ensures that during normal vehicle operation th0e compass performs auto-calibration functions to keep the compass sensors in their proper operating range. Whenever the ignition is On and the CT/CMTC/ EVIC receives PCI bus data indicating that engine RPM is greater than zero, auto-calibration is performed continuously. If the calibration information stored in the compass module memory is not within the normal range after a power-up cycle, the compass will display CAL. The CT/CMTC/EVIC will enter into the fast-cal mode until calibration is complete. To enter the compass into Manual Calibration mode, perform the following steps: - Drive the vehicle to an area away from any large metal objects or overhead power lines. - Ensure that the proper variance zone is selected. See "Setting Magnetic Zone Variance". - The ignition switch must be in the On position and the CMTC/EVIC display must not be blank. - Press the C/T button to view the Compass/ Temperature display. - Press and hold the RESET button (approximately 10 seconds) until CAL is displayed, then release the button. - Drive slowly, less than 5 MPH (8 KPH) in at least 1 complete 360-degree circle. - CAL will remain illuminated to alert the driver that the compass is in the calibration mode. - After calibration is complete, CAL will turn off. NOTE: For C/T Manual Calibration, perform the same procedure as above, but press and hold the C/T and US/M buttons until CAL is displayed. If the compass appears blank, unable to be calibrated, or the compass displays false indications,the vehicle must be demagnetized. SELF-CHECK DIAGNOSTICS The CT/CMTC/EVIC is capable of performing a diagnostic self check on its internal functions. Diagnostics may be performed using a DRBIII(R) or by using the following procedure: 1. For CMTC/EVIC: With the ignition switch in the OFF position, depress and hold the RESET and the STEP buttons. For CT: With the ignition switch in the OFF position, depress and hold the C/T and the US/M buttons. 2. Turn the ignition switch to the ON position. 3. Continue to hold both buttons until the software versions are displayed, then release the buttons. 4. All of the VFD segments will illuminate for 2-4 seconds. Check for segments that do not illuminate or illuminate all the time. 5. When the self-check is complete the EVIC will display one of the following messages: - PASS SELF TEST - FAILED SELF TEST - NOT RECEIVING J1850 MESSAGE When the self-check is complete the CT/CMTC will display one of the following messages: - PASS - FAIL - BUS 1. To exit the self-check mode: For the CMTC/EVIC: Depress the STEP or RESET button, or cycle the ignition switch and the CMTC/EVIC will return to normal operation. For the C/T: Depress the C/T or US/M button, or cycle the ignition switch and the CT will return to normal operation. If a Communication fault is displayed, refer to the symptom list. If a FAIL or FAILED is displayed, the CT/CMTC/EVIC must be replaced. AMBIENT TEMPERATURE SENSOR Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8751 The ambient air temperature is monitored by the FCM and displayed by the CT/CMTC/EVIC. The FCM receives a hardwire input from the ambient temperature sensor (ATS). The ATS is a variable resistor that operates on a 5-volt reference signal circuit hardwired from the FCM. The resistance in the ATS changes as the outside temperature rises or falls. The FCM senses the change in reference voltage through the ATS resistor. Based on the resistance of the ATS, the FCM is programmed to correspond to a specific temperature. The FCM stores and filters the ambient temperature data and transmits this data to the CMTC/EVIC via the PCI Bus. The ATS cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. AMBIENT TEMPERATURE SENSOR FAULT CODES The outside temperature function is supported by the ambient temperature sensor (ATS), a signal and ground circuit hardwired to the FCM, and the CMTC/EVIC display. If the ATS sense circuit is shorted to ground, the temp display will be 54° C (130° F) to indicate SHORT circuit condition. If the ATS sense circuit is open, the temp display will be -40° C (-40° F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the CMTC/EVIC VFD can be tested. The ATS is supported by the FCM. Ambient Temperature Sensor DTC's will be recorded in the FCM. The ATS can be diagnosed using the following Sensor Test. Test the ATS circuits using the diagnostics in the Body Diagnostic Procedures Manual. If the CMTC/EVIC passes the self-test, and the ATS, the circuits, and PCI bus communications are confirmed to be OK, but the CMTC/EVIC temperature display is inoperative or incorrect, replace the FCM. AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: - 0° C (32° F) Sensor Resistance = 29.33 - 35.99 Kilohms - 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kilohms - 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kilohms - 25° C (77° F) Sensor Resistance = 9.12 - 10.86 Kilohms 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kilohms - 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance values are not OK, replace the Sensor. HOMELINK(R) UNIVERSAL TRANSMITTER If equipped, HomeLink(R) Universal Transmitter is integrated into the overhead console. For added security it will operate home security systems that use coded signals known generically as Rolling Codes. The overhead console display provides visual feedback to the driver, indicating which HomeLink(R) transmitter channel button is being pressed. The HomeLink(R) can learn and store up to three separate transmitter radio frequency codes to operate garage door openers, security gates, and security lighting. The HomeLink(R) buttons are marked with one, two, or three dots. For complete information. TIRE PRESSURE MONITORING SYSTEM (TPMS) If equipped with the Tire Pressure Monitoring System (TPMS), each of the vehicles four wheels will have a valve stem with a pressure sensor and radio transmitter built in. Signals from the tire pressure Sensor/Transmitter are received and interpreted by the Sentry Key Remote Entry Module (SKREEM). Using the DRBIII(R), go to ANTI-THEFT for the SKREEM data. A Sensor/Transmitter in a mounted wheel will broadcast an RF frequency indicating its pressure once per minute when the vehicle is in drive mode. To activate the Sensor/Transmitter operation, the required SKREEM speed is 13 mph (20 km/h). Each Sensor/Transmitters broadcast is uniquely coded so that the SKREEM can monitor the states of each Sensor/Transmitter on the vehicle. The SKREEM TPMS does not use a magnet to relearn, it automatically learns while driving after a SKREEM or a Sensor/Transmitter has been replaced. TRAINING THE SKREEM If a Sensor/Transmitter is replaced, the vehicle has to be parked for at least 15 minutes for the system to be ready to learn the new Sensor/Transmitter ID code. The vehicle then must be driven for a minimum of five minutes with a minimum continuous speed above 13 mph (20 km/h). The system will learn the new Sensor/Transmitter and clear the DTC's automatically. The Sensor/ Transmitters are programmed at the assembly plant in this clockwise orientation: Sensor/Transmitter 1 = Left Front Sensor/Transmitter 2 = Right Front Sensor/Transmitter 3 = Right Rear Sensor/Transmitter 4 = Left Rear NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8752 1. If one or all Sensor/Transmitters cannot be trained, check for and avoid RF interference. 2. If one Sensor/Transmitter still cannot be trained, replace it and retry. 3. If all Sensor/Transmitters still fail to train, replace the SKREEM. PRESSURE THRESHOLDS The SKREEM will monitor the tire pressure signals from the Sensor/Transmitters and determine if any tire has gone below the low-pressure or above the high-pressure thresholds. Refer to the tables below: Low Tire Pressure Thresholds High Tire Pressure Thresholds *Tolerance ±6.9 kPa (1 PSI) ACTIVE FAULT AND SYSTEM ALERTS An active fault will be triggered when a system failure has been detected. When this occurs, the Instrument Cluster will illuminate the TPMS indicator and the SKREEM will store the fault code. An alert will be triggered when a tire pressure has gone below or above the set threshold pressure. When this occurs, the Instrument Cluster will flash the TPMS indicator. The SKREEM will request a secondary message to be displayed on the EVIC (if equipped). Only when a tire pressure has gone below the set threshold pressure will the SKREEM request the TPMS indicator to flash and display the EVIC message (if equipped). When a high pressure alert occurs, only the EVIC message will be displayed. This action will be displayed as long as the alert condition is active. Park Assist System The Park Assist System display activates an audible tone that changes from intermittent to continuous as the final two Light Emitting Diodes (LED's) are illuminated on one side or both sides of the display. The system detection length from the rear of the vehicle is 0.3 meters to 1.5 meters. This area extends around the rear side of the vehicle.The system detection height from the ground is 0.2 meters to about 1.5 meters. The radio mutes when the system activates its audible tone. When the driver selects Reverse or Neutral the system scans for objects behind the vehicle using four sensors located in the rear bumper. Objects can be detected from up to 1.5 meters. A warning display above the rear window provides both visible and audible warnings indicating the range of the object. The system is active only when the vehicle is in reverse or neutral for vehicle speeds less than 16 Km/h (10 mph). If the vehicles Parking/Emergency Brake is applied, the system is deactivated. The display contains two sets of yellow and red Light Emitting Diode's (LED's) that the driver can see in the rear view mirror. Each side of the vehicle has its own warning LED's. The system provides a visual warning by illuminating one or more yellow LED's as the vehicle gets closer to the object. As the vehicle continues to approaches the object, one red LED is illuminated and the system emits a series of short beeps. The tone will remain constant and both red LED's are illuminated once the vehicle is within 12 inches (30.5 cm) of the object. The system can be turned ON or OFF through the Electronic Vehicle Information Center (EVIC) when the vehicle is in PARK. If the park assist system is turned OFF, a single chime will sound and the EVIC will display the following message REAR PARK ASSIST OFF, when the vehicle is in reverse. - Ensure that the rear bumper is free of dirt and debris to keep the system operating properly. - Jackhammers, large trucks, and other vibrations could affect the performance of the system. - Ensure that the parking brake is not applied. If Service Park Assist System appears in the EVIC after making sure the rear bumper is clean, Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8753 proceed to diagnose the system using a scan tool and the appropriate diagnostic information. Power Door Lock System When the BCM receives input for a lock request from a door lock switch, RKE or cylinder lock switch (only with VTSS), it will turn the lock drivers on for a specified time of 375 msec. If the request is there beyond 375 msec, the BCM considers the door lock signal stuck. Once a door lock or unlock signal is stuck for longer than 10 seconds, the BCM will set a trouble code and the signal input is ignored until the stuck condition disappears. The door lock switches provide a variable amount of resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond to that command. DOOR LOCK INHIBIT When the key is in the ignition and in any position and either front door is open, the door lock switches LOCK functions are disabled. The UNLOCK functions are still functional. This protects against locking the vehicle with the keys still in the ignition. The RKE key fob will still lock the doors as usual. After the key is removed from the ignition or the doors are closed, the power door locks will operate normally. AUTOMATIC DOOR LOCKS This feature can be enabled or disabled by using either the DRBIII(R) or the customer programming method. When enabled all the doors will lock when the vehicle reaches a speed greater than 18 MPH (29 KMH) and all the doors are closed. If a door is opened and the vehicle slows to below 18 MPH (29 KMH), the door locks will operate again once all doors are closed and the speed is above 18 MPH (29 KMH). REMOTE KEYLESS ENTRY (RKE) The RKE transmitter uses radio frequency signals to communicate with the SKREEM module. The SKREEM is on the PCI bus. When the operator presses a button on the transmitter, it sends a specific request to the SKREEM. In turn the SKREEM sends the appropriate request over the PCI Bus to the: - Body Control Module (BCM) to control the door lock and unlock functions, the arming and disarming of the Vehicle Theft Security System (if equipped), and the activation of illuminated entry. - Integrated Power Module (IPM) to activate the park lamps, the headlamps, and the horn for horn chirp. - Power Liftgate Module (PLGM) to control the liftgate operation (double press). - Power Sliding Door Module (PSDM) to control the sliding door operation (double press). After pressing the lock button on the RKE transmitter, all of the door locks will lock, the illuminated entry will turn off (providing all doors are closed), and the vehicle theft security system (if equipped) will arm. After pressing the unlock button, on the RKE transmitter, one time, the driver doorlock will unlock, the illuminated entry will turn on the courtesy lamps, and the vehicle theft security system system (if equipped) will disarm. After pressing the unlock button a second time, the remaining door locks will unlock. The EVIC or the DRBIII(R) can reprogram this feature to unlock all of the door locks with one press of the unlock button. If the vehicle is equipped with the memory system, the memory message will identify which transmitter (1 or 2) sent the signal. The SKREEM is capable of retaining up to 8 individual access codes (8 transmitters). If the PRNDL is in any position except park, the SKREEM will disable the RKE. The 3 or 6 button transmitter uses 1-CR2032 battery. The minimum battery life is approximately 5 years based on 20 transmissions a day at 84° F (25° C). Use the DRBIII(R) or the Miller Tool 9001 RF Detector to test the RKE transmitter. Use the DRBIII(R) or the customer programming method to program the RKE system. However, the SKREEM will only allow RKE programming when the ignition is in the on position, the PRNDL is in park position, and the VTSS (if equipped) is disarmed. PANIC FUNCTION Pressing the panic button on the RKE transmitter will cause the headlamp relay, the park lamp relay, and the horn relay to pulsate, which in turn will cause the exterior lamps to flash and the horn to sound intermittently. It will also cause the courtesy lamp relay to actuate, turning on the courtesy lamps. Pressing the panic button again stops the headlamps and the park lamps from flashing and the horn from sounding. However, the courtesy lamps will remain on until either the BCM times out lamp operation or until the ignition is turned on. The panic feature operates for three minutes at a time, unless the operator cancels it, or the ignition is turned on. Actuating the headlamp, horn, park lamps, and courtesy lamps with the DRBIII(R) will verify if the circuits and the Integrated Power Module are OK. If the panic feature is still inoperable with all transmitters, it will be necessary to replace the SKREEM. If the function is inoperable with just one transmitter, then replace only that transmitter. ROLLING CODE The rolling code feature changes part of the transmitter message each time that it is used. The transmitter message and the receiver message increment together. Under certain conditions with a rolling code system (pressing a button on the RKE transmitter over 255 times outside the receiver range, battery replacement, etc.), the receiver and transmitter can fall out of synchronization. NOTE: The lock function works from the RKE transmitter even in an out of synchronization condition and therefore it could be verified by pressing the LOCK button on the RKE integrated key. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8754 To resynchronize, press and release the UNLOCK button on the RKE transmitter repeatedly (it may take up to eight cycles) while listening carefully for the power door locks in the vehicle to cycle, indicating that resynchronization has occurred. PROGRAMMABLE DOOR LOCK FEATURES - The RKE can be changed to unlock all doors with one press - The Automatic Door Locks can be enabled/ disabled - Auto Unlock on Exit can be enabled/disabled - RKE horn chirp on lock can be enabled/disabled - RKE optical chirp (turn signal lamps) can be enabled/disabled - Program a new RKE transmitter. - RKE linked to memory (if equipped with memory system) enabled/disabled (DRBIII(R) only). Allows memory to be operable only from the driver door switch. Rear Window Defog/Heated Mirror The defroster button located on the HVAC control controls the rear window defogger and the heated side view mirrors. When the defroster button is pushed, the HVAC control sends a bus message over the PCI bus to the Front Control Module (FCM) which controls the Rear Window Defogger relay. The defroster LED will illuminate when the defroster function is on. The defroster will function for 10 minutes or can be cycled off sooner by pressing the defroster button again. Vehicle Theft Security System The Vehicle Theft Security System (VTSS) is part of the Body Control Module (BCM). The BCM monitors the vehicle doors, liftgate (export only), hood (export only), and the ignition for unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps and the VTSS indicator lamp. The VTSS does not prevent engine operation, this is done with the Sentry Key Remote Entry Module (SKREEM). The VTSS indicator lamp will flash for approximately 15 seconds during the arming process. If there is no interruption during the arming process, upon completion the VTSS indicator lamp will flash at a slower rate. When the BCM receives an input to trigger the alarm, the BCM will control the outputs of the headlamps, horn, and VTSS lamp for approximately 15 minutes. Arming (Active and Passive) Active arming occurs when the ignition key is removed, the RKE transmitter or door key cylinders are used to lock the vehicle doors, whether the doors are open or closed. The arming process is complete only after all doors are closed. Passive arming occurs when the ignition key is removed, the driver door is opened, and the doors are locked with the power door lock switch, and the door is closed. Disarming (Active and Passive) Active disarming occurs when the RKE transmitter is used to unlock the vehicle doors. This disarming will also halt the alarm once it has been activated. Passive disarming occurs upon normal vehicle entry (unlocking driver door with the key) or turning the ignition switch on with a valid ignition key. This disarming will also halt the alarm once it has been activated. Tamper Alert The VTSS tamper alert will sound the horn three times upon disarming after an initial alarming has occurred to indicate a tamper condition has occurred. Manual Override The system will not arm if the doors are locked using the manual lock control or if the locks are actuated by an inside occupant after the doors are closed. Diagnosis For complaints about the Vehicle Theft Alarm triggering on its own, use the DRBIII(R) and read the Last VTSS Cause status. Arming Before arming, all doors, liftgate, and the hood must be completely closed. The system can only be armed by locking the doors with the RKE transmitter. Disarming To disarm the alarm system, use the RKE transmitter or turn the ignition on with a valid ignition key. This will also halt the alarm once it has been activated. NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system cannot be used in a vehicle that is not equipped with a vehicle theft security system. If the VTSS indicator lamp comes on after ignition on and stays on, the PCI Bus Communication with the powertrain Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8755 control module has possibly been lost. Power Folding Mirrors The power folding mirrors are powered to two positions: folded and unfolded. The driver may choose fold or unfold with a switch that is located on the right side of the steering column. The folding mirror switch grounds a sense wire that comes from the Body Control Module when it is placed in the fold position. The mirrors will move to the position designated by the switch whether the ignition switch is the On or Off position and both front doors are closed. When the Power Folding Mirror switch is left in the fold position during a vehicle exit the mirrors will automatically unfold then refold after both front doors are closed. This is to prevent mirror contact with either front door when opened. When opening either front door, the Body Control Module will unfold the mirrors in the following manner depending on which front door is opened. If the driver door is opened, only the driver side mirror will unfold. If the passenger door is opened, both mirrors will unfold. The passenger mirror is prevented from unfolding when the driver's door is opened by the Passenger Folding Mirror Relay, which opens the driver circuit to the passenger side mirror. Power Liftgate System POWER LIFTGATE The power liftgate (PLG) system is activated through the use of the following: remote keyless entry (RKE), overhead console switches, outside liftgate handle switch or the DRBIII(R). These inputs are hardwired to the body control module (BCM) and can be monitored with a diagnostic tool. The BCM will send the message via PCI bus to the power liftgate module (PLGM). The liftgate must be in the full open or full closed position to operate. Once the BCM sends a button activation message to the PLGM, the module shall read all inputs, outputs and vehicle conditions to determine whether it shall open, close or inhibit the PLG operation. Once the PLGM determines the vehicle conditions are safe for operation, the PLGM will initiate a chime for 2 seconds prior to the liftgate activation and 2 seconds during the open or close cycle. During an opening or closing cycle, the PLGM can detect an obstacle present should it meet sufficient resistance by the hall effect sensors (integrated in the gear motor assembly GMA).During an open cycle, multiple liftgate activations (RKE, overhead console, B pillar) are ignored until the liftgate reaches the full open position. However, during a close cycle, a 2nd liftgate activation (RKE, overhead console, B pillar) will reverse the liftgate to the full open position. If the engine is cranked during a power open/close the PLG will pause then resume after engine cranking. In addition, if the vehicle is placed in gear during an open cycle, the PLG shall reverse direction and begin closing. If the vehicle is placed in gear during a closing cycle, the PLG shall continue closing until fully closed. If the outside handle is activated during an open cycle, the PLG will become a full manual liftgate. If the outside handle is activated during a close cycle, the PLG shall reverse direction of travel to the full open position. DIAGNOSTIC FEATURES The PLG can be flashed on vehicle via PCI bus with a DRBIII(R) diagnostic tool. The DRBIII(R) can read all inputs, actuate all outputs, read module information, and read diagnostic trouble codes. As a reminder, some DTC's can be set during normal PLG operation. SYSTEM INHIBITORS 1. Battery voltage too high or too low (above 16 V, below 9.5 V) 2. Vehicle in gear 3. Vehicle speed > 0 mph/km/h 4. Outside temperature too high, above 143° F (62° C) or too low, below -12° F (-24° C). 5. O/H console lockout will inhibit the B pillar switches only. 6. Liftgate locked will inhibit all interior switches from opening (overhead console). A locked liftgate can be power closed. 7. Pinch Sensor switch stuck shall inhibit the power close feature. Power Sliding Door System POWER SLIDING DOOR The Power Sliding Door (PSD) system is activated through the use of the following: Remote Keyless Entry (RKE), overhead console switches, B pillar switches or the DRBIII(R). These inputs are hardwired to the body control module (BCM) and can be monitored with a diagnostic tool. The BCM will send the message via PCI bus to the power sliding door module (PSDM). The sliding door must be in the full open or full closed position to operate. Once the BCM sends a button activation message to the PSDM, the module shall read all inputs, outputs and vehicle conditions to determine whether it shall open, close or inhibit the PSD operation. During an opening or closing cycle, the PSDM can detect an obstacle present should it meet sufficient resistance by the hall effect sensors (integrated in the drive motor). During an open cycle, multiple door activations (RKE, overhead console, B pillar) are ignored until the door reaches the full open position. However, during a close cycle, a 2nd door activation (RKE, overhead console, B pillar) will reverse the door to the full open position. If the engine is cranked during a power open/close the PSD will pause then resume after engine cranking. In addition, if the vehicle is placed in gear during an open cycle, the PSD shall reverse direction and begin closing. If the vehicle is placed in gear during a closing cycle, the PSD shall continue closing until fully closed. If the inside or outside handle is activated during an open or close cycle, the PSD will become a full manual sliding door. The child lockout is mechanical only and has no effect on the B-pillar switch as it did in previous models. There is only one part number for the power sliding door module (PSDM). The driver sliding door harness has an additional ground circuit which will Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8756 identify it as the driver side. This eliminates the need for a left and a right side module. DIAGNOSTIC FEATURES The PSDM can be flashed on vehicle via PCI bus with a DRBIII(R) diagnostic tool. The DRBIII(R) can read all inputs, actuate all outputs, read module information, and read diagnostic trouble codes. As a reminder, some DTC's can be set during normal PSD operation. SYSTEM INHIBITORS 1. Battery voltage too high or too low (above 16 V, below 9.5 V) 2. Vehicle in gear 3. Vehicle speed > 0 mph/km/h 4. O/H console lockout will inhibit the B pillar switches 5. Doors locked will inhibit all interior switches from opening (Overhead Console, B Pillar). A locked sliding door can be power closed. Wiper System FRONT WIPER The front wiper/washer system consists of the following features: lo-hi-speed, mist wipers, intermittent wipers and wipe after wash. The front wiper system is only active when the ignition switch is in the RUN/ACC position. The vehicle operator selects the front wiper function using the front wiper switch (a resistive multiplexed stalk switch) which is integral to the Multi-Function Switch. The front wiper switch is hardwired to the Body Control Module (BCM). Upon receiving a wiper switch signal, the BCM sends a PCI Bus message to the Front Control Module (FCM). The FCM controls the ON/ OFF relay, the HIGH/LOW relay and the front and rear washer pump motors. The Wiper system utilizes the BCM to control the on/off and hi/low relays for the low and hi speed wiper functions, intermittent wiper delay as the switch position changes, pulse wipe, wipe after wash mode and wiper motor functions. The BCM uses the vehicle speed input to double the usual delay time below 10 MPH (16 KPH). SPEED SENSITIVE INTERMITTENT WIPE MODE There are 5 individual delay time settings with a minimum delay of 1.7 seconds to a maximum of 18.4 seconds. When the vehicle speed is under 10 MPH (16 KPH), the delay time is doubled, providing a delay range of 3.4 seconds to 36.8 seconds. PULSE WIPE When the wiper is in the off position and the driver presses the wash button for more than 0.062 seconds, but less than 0.5 seconds,2 wipe cycles in low speed mode will be provided. PARK AFTER IGNITION OFF Because the wiper relays are powered from the battery, the BCM can run the wipers to park after the ignition is turned off. WIPE AFTER WASH When the driver presses the wash button for over 0.5 seconds and releases it, the wiper will continue to run for 2 additional wipe cycles. REAR WIPER The rear wiper/washer system consists of the following features: mist wipers, intermittent wipers and wipe after wash. The rear wiper system is only active when the ignition switch is in the RUN/ACC position. The vehicle operator selects the rear wiper function using one of the three buttons on the dash mounted rear wiper switch. The rear wiper switch is hardwired to the Body Control Module (BCM). Upon receiving a wiper switch signal, the BCM provides 12 volts to the rear wiper motor. Rear washer occurs when the BCM receives a rear washer switch ON input. The BCM sends a PCI Bus message to the FCM requesting rear washer on. The FCM activates the rear washer by providing a ground for the rear washer motor. SPEED SENSITIVE INTERMITTENT WIPE MODE The delay setting of the rear wiper system is based solely on the vehicle speed. The delay time is defined as the amount of time from the start of a wipe to the beginning of the next wipe. The rear wiper system delay time is based on the following: 7.75 - (MPH x 0.05) = Seconds delay Examples:At zero (0) MPH the delay is 7.75 seconds. At 100 MPH the delay is 2.75 seconds. WIPE AFTER WASH When the driver presses the wash button for over 1.5 seconds and releases it,the wiper will continue to run for 2 additional wipe cycles. Telecommunications HANDS FREE PHONE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > System Description > Page 8757 OVERVIEW The vehicle telecommunications system consists of a Hands Free Module, Rear View Mirror, and a Blue-tooth Hands Free Profile enabled cell phone. The system allows vehicle occupants to use voice recognition technology to make, receive and screen phone calls without physically handling a cell phone. The system has a programmable phone book that can prevent the vehicle operator from becoming distracted searching for a specific number. Seven different wireless phones can be programmed to operate each individual system. Each of the seven phones is given a rank of priority when programmed. OPERATION Incoming phone messages are transmitted to the vehicle occupants through the vehicles audio system when the ignition is on and the wireless phone is on. Upon receiving the signal from an incoming phone call, the vehicle audio system will fade out the current CD/DVD or radio output. The vehicle occupants are then directed to accept or reject the call.Outgoing audio messages are received through the microphone located in the rearview mirror then transmitted via hardwire to the Hands Free Module and finally transmitted through the wireless phone. Volume of the voice prompts and incoming conversation is controlled using the vehicles radio audio controls and steering wheel controls if equipped. The rear view mirror contains a Phone Switch, Voice Recognition Switch and a microphone. The rear view mirror transmits these inputs via hardwired circuits to the Hands Free Module. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Body Control Module: Symptom Related Diagnostic Procedures Air Bag System Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Any Station Preset Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8760 Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8761 POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Test 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8762 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Pause/Play Switch Inoperative Test 1 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8763 Test 1 SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Remote Radio Controls Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8764 Test 4 - 7 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8765 Test 8 - 9 SYMPTOM REMOTE RADIO CONTROLS INOPERATIVE POSSIBLE CAUSES - Open radio control MUX circuit at the switch - Open radio control MUX return circuit at the switch - Remote radio switch - Body control module - internal short - Open clockspring - Open radio control MUX circuit - Open radio control MUX return circuit - Body control module - open internal Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8766 Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8767 POSSIBLE CAUSES - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure ATC Head LED(s)/Backlighting Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8768 Test 1 - 3 Test 4 - 5 SYMPTOM ATC HEAD LED(S)/BACK LIGHTING INOPERATIVE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8769 POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - ATC - LED(s) inoperative - ATC - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8770 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8771 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8772 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8773 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8774 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM FUSE #10 - Fused front blower motor relay output circuit shorted to ground - Blower motor shorted to ground - Front blower power module shorted to ground - Ground circuit open - Blower motor control circuit shorted to voltage - Blower motor control circuit open - Front blower power module open - Automatic temperature control module open - Check blower motor operation - Front blower power module open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8775 Test 1 Test 2 SYMPTOM FRONT BLOWER RUNS AT ONLY ONE SPEED Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8776 POSSIBLE CAUSES - Blower motor control circuit shorted to ground - Automatic temperature control module - Front blower power module HVAC System Test Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8777 Test 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8778 Test 6 Test 7 SYMPTOM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8779 HVAC SYSTEM TEST POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active ATC DTC's - Check for AC cooldown test fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear ATC Switch LED(s)/Backlighting Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8780 Test 4 - 5 SYMPTOM REAR ATC SWITCH LED(S)/BACK LIGHTING INOPERATIVE POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - Rear ATC switch - LED(s) inoperative - Rear ATC switch - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8781 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8782 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8783 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8784 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8785 Test 15 - 16 SYMPTOM REAR BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM Fuse #12 - Fused rear blower relay output circuit shorted to ground - Blower motor shorted to ground - Rear blower motor power module shorted to ground - Ground circuit open - Rear blower motor control circuit shorted to voltage - Rear blower motor control circuit open - Rear blower motor power module open - Automatic temperature control module open - Check blower motor operation - Rear blower motor power module open - IPM - open circuit - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8786 Test 1 Test 2 SYMPTOM REAR BLOWER RUNS AT ONLY ONE SPEED POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8787 - Rear blower motor control circuit shorted to ground - Automatic temperature control module - Rear blower motor power module Chime Inoperative Test 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE POSSIBLE CAUSES - Use DRB to actuate chime - Chime driver circuit - open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8788 - Chime driver circuit - short to ground - Chime driver circuit - short to voltage - Instrument cluster - BCM Key In Ignition and Drivers Door Open Chime Not Operating Properly Test 1 - 3 SYMPTOM KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME NOT OPERATING PROPERLY POSSIBLE CAUSES - DRB chime actuator - Driver door ajar status - Ignition switch - Body control module Vehicle Speed Warning Chime Problem Test 1 SYMPTOM PROBLEM WITH THE VEHICLE SPEED WARNING CHIME POSSIBLE CAUSES - Incorrect country code programmed in BCM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8789 - Body control module Left Front Door Ajar Switch Sense Circuit Open Test 1 - 4 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Left front door ajar switch ground circuit open - Left front door (lock motor) ajar switch - Left front door ajar switch sense circuit open - Body control module internal malfunction Left Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8790 Test 1 - 2 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left front door (lock motor) ajar switch shorted to ground - Left front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Left Sliding Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8791 Test 1 - 3 Test 4 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Left sliding door ajar switch sense circuit open - Left sliding door ajar switch sense circuit open - Body control module internal malfunction Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8792 - Left sliding door lock motor/ajar switch (latch assy). Left Sliding Door Ajar Switch Sense Circuit Shorted to Ground Test 1 - 3 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left sliding door lock motor/ajar switch shorted to ground - Left sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Left sliding door lock motor/ajar switch (latch assy). Liftgate Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8793 Test 1 - 4 SYMPTOM LIFTGATE AJAR CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Liftgate ajar switch ground circuit open - Liftgate ajar switch (cinch/release motor) - Liftgate ajar switch sense circuit open - Body control module internal malfunction Liftgate Ajar Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8794 Test 1 - 2 SYMPTOM LIFTGATE AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Liftgate ajar switch shorted to ground - Liftgate ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8795 Test 1 - 4 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Right front door ajar switch ground circuit open - Right front door (lock motor) ajar switch - Right front door ajar switch sense circuit open - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8796 Test 1 - 2 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right front door (lock motor) ajar switch shorted to ground - Right front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Sliding Door Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8797 Test 1 - 3 Test 4 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Right sliding door ajar switch sense circuit open - Right sliding door ajar switch sense circuit open - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8798 Right Sliding Door Ajar Circuit Shorted to Ground Test 1 - 3 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right sliding door lock motor/ajar switch shorted to ground - Right sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) A/C Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8799 Test 1 - 2 Test 3 SYMPTOM A/C STATUS INDICATOR FLASHING - MTC POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Blend/Mode/Recirc Door Operation Improper -- Dual & Three-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8800 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8801 Test 4 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8802 Test 7 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8803 Test 10 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER -- DUAL & THREE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Passenger blend door actuator/linkage/door - Driver blend door actuator/linkage/door - Recirculation door actuator/linkage/door - Rear mode door actuator/linkage/door - Rear blend door actuator/linkage/door Blend/Mode/Recirc Door Operation Improper --Single-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8804 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8805 Test 4 - 7 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER --SINGLE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Blend door actuator/linkage/door - Recirculation door actuator/linkage/door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8806 Front A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Test 4 SYMPTOM FRONT A/C - HEATER CONTROL ILLUMINATION INOPERATIVE -MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - A/C - heater control module - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8807 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8808 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8809 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8810 Test 11 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8811 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #10 - Fused front blower motor relay output circuit shorted to ground - Front blower motor resistor block shorted to ground - Front blower motor resistor block shorted to ground - Blower motor - Blower motor - A/C - heater control module - Ground circuit open - Blower motor high driver circuit open - Front blower motor resistor block open - Front blower motor resistor block open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Motor Speeds Incorrect - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8812 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8813 Test 3 - 5 SYMPTOM FRONT BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Blower motor driver circuit(s) shorted to ground - Blower motor driver circuit(s) shorted to voltage - Blower motor driver circuits shorted together - A/C - heater control module - speeds incorrect - Blower motor driver circuit(s) open - Blower motor resistor block - open speed HVAC System Test - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8814 Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8815 Test 5 Test 5 SYMPTOM HVAC SYSTEM TEST - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8816 POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active HVAC DTC's and system tests fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8817 Test 4 - 5 SYMPTOM REAR A/C - HEATER CONTROL ILLUMINATION INOPERATIVE - MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - Inoperative bulb - Ground circuit open - Rear blower rear control switch - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8818 Test 1 - 2 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8819 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8820 Test 11 - 14 SYMPTOM REAR BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #12 - Fused rear blower motor relay output circuit shorted to ground - Blower motor - Ground circuit open - A/C - heater control module - Check for power to rear blower motor - Blower motor - Rear blower high speed circuit open - Rear blower motor high circuit open - Rear blower motor resistor block - IPM - open circuit Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8821 - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Motor Speeds Incorrect - MTC Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8822 Test 3 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8823 Test 6 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8824 Test 10 SYMPTOM REAR BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to ground - A/C - heater control module - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to voltage - Rear blower motor front control feed circuit shorted to voltage - Rear blower driver CKT(s) shorted to rear blower front control feed CKT - Rear blower motor driver circuits shorted together - A/C - heater control module - Rear blower motor driver circuit(s) open - Rear blower motor resistor block Rear Blower Rear Control Switch INOP In One or More Speeds - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8825 Test 1 - 2 Test 3 SYMPTOM REAR BLOWER REAR CONTROL SWITCH INOP IN ONE OR MORE SPEEDS - MTC POSSIBLE CAUSES - Rear blower motor driver circuit(s) open - Rear blower rear control switch - Rear blower motor front control feed circuit open - A/C - heater control module Recirc Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8826 Test 1 - 2 Test 3 SYMPTOM RECIRC STATUS INDICATOR FLASHING - MTC TEST NOTE This symptom is diagnosed using the test A/C STATUS INDICATOR FLASHING - MTC. POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Any PCI Bus Indicator Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8827 Test 1 - 4 SYMPTOM ANY PCI BUS INDICATOR INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - No response - instrument cluster - No response - ECM / PCM - Indicator inoperative - Instrument cluster Seat Belt Indicator Always On Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8828 Test 1 SYMPTOM SEAT BELT INDICATOR ALWAYS ON POSSIBLE CAUSES - ACM seat belt indicator command present - Instrument cluster Overhead Console Test 1 - 4 SYMPTOM REPAIRING CMTC DISPLAYS DOUBLE DASH (- - ) IN TEMP DISPLAY POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8829 - No response - PCI BUS - powertrain control module - CMTC BUS message failure - Compass mini-trip computer - Ambient temperature sensor - PCM ambient air temperature sensor DTC present - CMTC internal Left Cylinder Lock Switch Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8830 Test 4 - 5 SYMPTOM LEFT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - left cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - left cylinder lock switch MUX short to voltage Remote Keyless Entry Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8831 Test 1 - 4 Test 5 - 6 SYMPTOM REMOTE KEYLESS ENTRY INOPERATIVE POSSIBLE CAUSES - DTC present - SKREEM DTC present - Test transmitter with tester - RKE transmitter inoperative - RKE transmitter not programmed - SKREEM module - RKE inoperative - SKREEM module - RKE inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8832 Right Cylinder Lock Switch Inoperative Test 1 - 3 Test 4 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8833 SYMPTOM RIGHT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - right cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - right cylinder lock switch MUX short to voltage Power Doors - Liftgate Test 1 - 4 SYMPTOM POWER LIFTGATE INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Power Doors - Sliding Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8834 Test 1 - 4 SYMPTOM POWER SLIDING DOOR INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Alarm Trips On Its Own Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8835 Test 1 - 4 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - Last VTSS cause - Attempt to trip alarm - Intermittent condition Left Front Door Does Not Trip VTSS Test 1 SYMPTOM LEFT FRONT DOOR DOES NOT TRIP VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8836 POSSIBLE CAUSES - Body control module - Check DRBIII(R) for driver door ajar response Left Sliding Door Does Not Trip VTSS Test 1 SYMPTOM LEFT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Monitor DRBIII(R) for left sliding door ajar status - Body control module Right Front Door Does Not Trip VTSS Test 1 SYMPTOM RIGHT FRONT DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for passenger door ajar response - Body control module Right Sliding Door Does Not Trip VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8837 Test 1 SYMPTOM RIGHT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for right rear door ajar response - Body control module VTSS Will Not Arm Test 1 - 3 SYMPTOM VTSS WILL NOT ARM POSSIBLE CAUSES - Check the VTSS status - Check for BCM DTC's and VTSS arming inhibitors - Check for PCI BUS communication of instrument cluster and SKIM - Body control module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8838 Body Control Module: Component Tests and General Diagnostics Six Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation Road Testing ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. WARNING: REASSEMBLE ALL COMPONENTS BEFORE ROAD TESTING A VEHICLE. DO NOT TRY TO READ THE DRBIII(R) SCREEN OR OTHER TEST EQUIPMENT DURING A TEST DRIVE. DO NOT HANG THE DRBIII(R) OR OTHER TEST EQUIPMENT FROM THE REARVIEW MIRROR DURING A TEST DRIVE. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIII(R) OR OTHER TEST EQUIPMENT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Vehicle Preparation For Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Glossary of Terms ABS antilock brake system ACT actuator APS adjustable pedals system ATC automatic temperature control BCM body control module BPS bladder pressure sensor BTS belt tension sensor CAB controller antilock brake CMTC compass/mini-trip computer CPA connector positive assurance DAB driver airbag DCHA diesel cabin heater assist (cabin heater) DLC data link connector DTC diagnostic trouble code DR driver EBL electric back lite (rear window defogger) ECM engine control module EVIC electronic vehicle information center FCM front control module GCC Gulf Coast Countries HE hall effect HFM hands free module HVAC heater ventilation, air conditioning IPM integrated power module KNB knee blocker airbag LDU lower drive unit LHD left hand drive MIC mechanical instrument cluster MTC manual temperature control MSMAPM memory seat/mirror/adjustable pedals module NAV navigation NGC next generation controller OBD on board diagnostics OCM occupant classification module OCS occupant classification system OCSVR occupant classification system verification required ODO odometer ORC occupant restraint controller PAB passenger airbag PASS passenger PCI Programmable Communication Interface (vehicle communication bus) PCM powertrain control module PDC power distribution center PLG power liftgate Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8839 PLGM power liftgate module PSD power sliding door PSDM power sliding door module PWM pulse width modulated RHD Right Hand Drive RKE remote keyless entry RX receive SAB seat airbag SBS seat belt switch SBT seat belt tensioner SKREEM sentry key remote entry module SQUIB also called initiator (located inside airbag) SRS supplemental restraint system TCM transmission control module TPMS tire pressure monitor system TX transmit VFD vacuum fluorescent display VTSS vehicle theft security system Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8840 Body Control Module: Testing and Inspection Diagnostic Trouble Code Descriptions For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions Diagnostic Trouble Code Tests and Associated Procedures For Information regarding diagnosis of all B, C, P, U and Manufacturer Codes See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures Air Bag System Test 1 SYMPTOM AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES POSSIBLE CAUSES - Airbag warning indicator on without active trouble codes - Instrument cluster problems AM/FM Switch Inoperative Test 1 SYMPTOM AM/FM SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Any Station Preset Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8841 Test 1 SYMPTOM ANY STATION PRESET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Balance Inoperative Test 1 SYMPTOM BALANCE INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure CD Eject Switch Inoperative Test 1 SYMPTOM CD EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8842 POSSIBLE CAUSES - Internal failure Equalizer Inoperative Test 1 SYMPTOM EQUALIZER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Fader Inoperative Test 1 SYMPTOM FADER INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure FF/RW Switch Inoperative Test 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8843 SYMPTOM FF/RW SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure HOUR/MINUTE Switches Inoperative Test 1 SYMPTOM HOUR/MINUTE SWITCHES INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Pause/Play Switch Inoperative Test 1 SYMPTOM PAUSE/PLAY SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure PWR Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8844 Test 1 SYMPTOM PWR SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Remote Radio Controls Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8845 Test 4 - 7 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8846 Test 8 - 9 SYMPTOM REMOTE RADIO CONTROLS INOPERATIVE POSSIBLE CAUSES - Open radio control MUX circuit at the switch - Open radio control MUX return circuit at the switch - Remote radio switch - Body control module - internal short - Open clockspring - Open radio control MUX circuit - Open radio control MUX return circuit - Body control module - open internal Scan Switch Inoperative Test 1 SYMPTOM SCAN SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Seek Switch Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8847 Test 1 SYMPTOM SEEK SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Set Switch Inoperative Test 1 SYMPTOM SET SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tape Eject Switch Inoperative Test 1 SYMPTOM TAPE EJECT SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8848 POSSIBLE CAUSES - Internal failure Time Switch Inoperative Test 1 SYMPTOM TIME SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure Tune Switch Inoperative Test 1 SYMPTOM TUNE SWITCH INOPERATIVE TEST NOTE This symptom is diagnosed using the test CASSETTE PLAYER INOP. POSSIBLE CAUSES - Internal failure ATC Head LED(s)/Backlighting Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8849 Test 1 - 3 Test 4 - 5 SYMPTOM ATC HEAD LED(S)/BACK LIGHTING INOPERATIVE Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8850 POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - ATC - LED(s) inoperative - ATC - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8851 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8852 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8853 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8854 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8855 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM FUSE #10 - Fused front blower motor relay output circuit shorted to ground - Blower motor shorted to ground - Front blower power module shorted to ground - Ground circuit open - Blower motor control circuit shorted to voltage - Blower motor control circuit open - Front blower power module open - Automatic temperature control module open - Check blower motor operation - Front blower power module open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8856 Test 1 Test 2 SYMPTOM FRONT BLOWER RUNS AT ONLY ONE SPEED Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8857 POSSIBLE CAUSES - Blower motor control circuit shorted to ground - Automatic temperature control module - Front blower power module HVAC System Test Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8858 Test 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8859 Test 6 Test 7 SYMPTOM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8860 HVAC SYSTEM TEST POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active ATC DTC's - Check for AC cooldown test fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear ATC Switch LED(s)/Backlighting Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8861 Test 4 - 5 SYMPTOM REAR ATC SWITCH LED(S)/BACK LIGHTING INOPERATIVE POSSIBLE CAUSES - Check for ATC DTC's - Check for BCM DTC's - Rear ATC switch - LED(s) inoperative - Rear ATC switch - back lighting inoperative - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8862 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8863 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8864 Test 11 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8865 Test 12 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8866 Test 15 - 16 SYMPTOM REAR BLOWER MOTOR INOPERATIVE POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM Fuse #12 - Fused rear blower relay output circuit shorted to ground - Blower motor shorted to ground - Rear blower motor power module shorted to ground - Ground circuit open - Rear blower motor control circuit shorted to voltage - Rear blower motor control circuit open - Rear blower motor power module open - Automatic temperature control module open - Check blower motor operation - Rear blower motor power module open - IPM - open circuit - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Runs At Only One Speed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8867 Test 1 Test 2 SYMPTOM REAR BLOWER RUNS AT ONLY ONE SPEED POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8868 - Rear blower motor control circuit shorted to ground - Automatic temperature control module - Rear blower motor power module Chime Inoperative Test 1 - 4 Test 5 SYMPTOM CHIME INOPERATIVE POSSIBLE CAUSES - Use DRB to actuate chime - Chime driver circuit - open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8869 - Chime driver circuit - short to ground - Chime driver circuit - short to voltage - Instrument cluster - BCM Key In Ignition and Drivers Door Open Chime Not Operating Properly Test 1 - 3 SYMPTOM KEY IN IGNITION AND DRIVER'S DOOR OPEN CHIME NOT OPERATING PROPERLY POSSIBLE CAUSES - DRB chime actuator - Driver door ajar status - Ignition switch - Body control module Vehicle Speed Warning Chime Problem Test 1 SYMPTOM PROBLEM WITH THE VEHICLE SPEED WARNING CHIME POSSIBLE CAUSES - Incorrect country code programmed in BCM Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8870 - Body control module Left Front Door Ajar Switch Sense Circuit Open Test 1 - 4 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Left front door ajar switch ground circuit open - Left front door (lock motor) ajar switch - Left front door ajar switch sense circuit open - Body control module internal malfunction Left Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8871 Test 1 - 2 SYMPTOM LEFT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left front door (lock motor) ajar switch shorted to ground - Left front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Left Sliding Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8872 Test 1 - 3 Test 4 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Left sliding door ajar switch sense circuit open - Left sliding door ajar switch sense circuit open - Body control module internal malfunction Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8873 - Left sliding door lock motor/ajar switch (latch assy). Left Sliding Door Ajar Switch Sense Circuit Shorted to Ground Test 1 - 3 SYMPTOM LEFT SLIDING DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Left sliding door lock motor/ajar switch shorted to ground - Left sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Left sliding door lock motor/ajar switch (latch assy). Liftgate Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8874 Test 1 - 4 SYMPTOM LIFTGATE AJAR CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Liftgate ajar switch ground circuit open - Liftgate ajar switch (cinch/release motor) - Liftgate ajar switch sense circuit open - Body control module internal malfunction Liftgate Ajar Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8875 Test 1 - 2 SYMPTOM LIFTGATE AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Liftgate ajar switch shorted to ground - Liftgate ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8876 Test 1 - 4 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT OPEN POSSIBLE CAUSES - Intermittent condition - Right front door ajar switch ground circuit open - Right front door (lock motor) ajar switch - Right front door ajar switch sense circuit open - Body control module internal malfunction Right Front Door Ajar Switch Sense Circuit Shorted to Ground Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8877 Test 1 - 2 SYMPTOM RIGHT FRONT DOOR AJAR SWITCH SENSE CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right front door (lock motor) ajar switch shorted to ground - Right front door ajar switch sense circuit shorted to ground - Body control module internal malfunction Right Sliding Door Ajar Circuit Open Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8878 Test 1 - 3 Test 4 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT OPEN POSSIBLE CAUSES - Ground circuit open - Right sliding door ajar switch sense circuit open - Right sliding door ajar switch sense circuit open - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8879 Right Sliding Door Ajar Circuit Shorted to Ground Test 1 - 3 SYMPTOM RIGHT SLIDING DOOR AJAR CIRCUIT SHORTED TO GROUND POSSIBLE CAUSES - Right sliding door lock motor/ajar switch shorted to ground - Right sliding door ajar switch sense circuit shorted to ground - Body control module internal malfunction - Right sliding door lock motor/ajar switch (latch assy) A/C Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8880 Test 1 - 2 Test 3 SYMPTOM A/C STATUS INDICATOR FLASHING - MTC POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Blend/Mode/Recirc Door Operation Improper -- Dual & Three-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8881 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8882 Test 4 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8883 Test 7 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8884 Test 10 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER -- DUAL & THREE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Passenger blend door actuator/linkage/door - Driver blend door actuator/linkage/door - Recirculation door actuator/linkage/door - Rear mode door actuator/linkage/door - Rear blend door actuator/linkage/door Blend/Mode/Recirc Door Operation Improper --Single-Zone MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8885 Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8886 Test 4 - 7 SYMPTOM BLEND/MODE/RECIRC DOOR OPERATION IMPROPER --SINGLE-ZONE MTC POSSIBLE CAUSES - Check for actuator circuit test fault messages - Check for active HVAC DTC's - Check for HVAC do0r recalibration fault messages - Mode door actuator/linkage/door - Blend door actuator/linkage/door - Recirculation door actuator/linkage/door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8887 Front A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Test 4 SYMPTOM FRONT A/C - HEATER CONTROL ILLUMINATION INOPERATIVE -MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - A/C - heater control module - Panel lamps driver circuit open - Body control module - panel lamps driver open Front Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8888 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8889 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8890 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8891 Test 11 - 14 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8892 Test 15 - 16 SYMPTOM FRONT BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #10 - Fused front blower motor relay output circuit shorted to ground - Front blower motor resistor block shorted to ground - Front blower motor resistor block shorted to ground - Blower motor - Blower motor - A/C - heater control module - Ground circuit open - Blower motor high driver circuit open - Front blower motor resistor block open - Front blower motor resistor block open - IPM - open circuit - IPM - open circuit - Front blower motor relay - IPM - open circuit - Fused front blower motor relay output circuit open Front Blower Motor Speeds Incorrect - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8893 Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8894 Test 3 - 5 SYMPTOM FRONT BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Blower motor driver circuit(s) shorted to ground - Blower motor driver circuit(s) shorted to voltage - Blower motor driver circuits shorted together - A/C - heater control module - speeds incorrect - Blower motor driver circuit(s) open - Blower motor resistor block - open speed HVAC System Test - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8895 Test 1 - 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8896 Test 5 Test 5 SYMPTOM HVAC SYSTEM TEST - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8897 POSSIBLE CAUSES - Attempt to communicate with the PCM/ECM, the BCM, and the FCM - Check for HVAC related DTC's in the PCM/ECM - Check for BCM DTC's - Check for FCM DTC's - Check for active HVAC DTC's and system tests fault messages - Check for HVAC related DTC's in the PCM/ECM - Manual A/C system test Rear A/C - Heater Control Illumination Inoperative -MTC Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8898 Test 4 - 5 SYMPTOM REAR A/C - HEATER CONTROL ILLUMINATION INOPERATIVE - MTC POSSIBLE CAUSES - Check for HVAC DTC's - Check for BCM DTC's - Inoperative bulb - Ground circuit open - Rear blower rear control switch - Panel lamps driver circuit open - Body control module - panel lamps driver open Rear Blower Motor Inoperative - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8899 Test 1 - 2 Test 3 - 6 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8900 Test 7 - 10 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8901 Test 11 - 14 SYMPTOM REAR BLOWER MOTOR INOPERATIVE - MTC POSSIBLE CAUSES - Front control module (FCM) DTC(s) present - IPM fuse #12 - Fused rear blower motor relay output circuit shorted to ground - Blower motor - Ground circuit open - A/C - heater control module - Check for power to rear blower motor - Blower motor - Rear blower high speed circuit open - Rear blower motor high circuit open - Rear blower motor resistor block - IPM - open circuit Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8902 - IPM - open circuit - Rear blower motor relay - IPM - open circuit - Fused rear blower motor relay output circuit open Rear Blower Motor Speeds Incorrect - MTC Test 1 - 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8903 Test 3 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8904 Test 6 - 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8905 Test 10 SYMPTOM REAR BLOWER MOTOR SPEEDS INCORRECT - MTC POSSIBLE CAUSES - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to ground - A/C - heater control module - Rear blower rear control switch - Rear blower motor driver circuit(s) shorted to voltage - Rear blower motor front control feed circuit shorted to voltage - Rear blower driver CKT(s) shorted to rear blower front control feed CKT - Rear blower motor driver circuits shorted together - A/C - heater control module - Rear blower motor driver circuit(s) open - Rear blower motor resistor block Rear Blower Rear Control Switch INOP In One or More Speeds - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8906 Test 1 - 2 Test 3 SYMPTOM REAR BLOWER REAR CONTROL SWITCH INOP IN ONE OR MORE SPEEDS - MTC POSSIBLE CAUSES - Rear blower motor driver circuit(s) open - Rear blower rear control switch - Rear blower motor front control feed circuit open - A/C - heater control module Recirc Status Indicator Flashing - MTC Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8907 Test 1 - 2 Test 3 SYMPTOM RECIRC STATUS INDICATOR FLASHING - MTC TEST NOTE This symptom is diagnosed using the test A/C STATUS INDICATOR FLASHING - MTC. POSSIBLE CAUSES - AC cooldown test needs to be run - HVAC door recalibration needs to be run Any PCI Bus Indicator Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8908 Test 1 - 4 SYMPTOM ANY PCI BUS INDICATOR INOPERATIVE POSSIBLE CAUSES - No response - PCI BUS - No response - instrument cluster - No response - ECM / PCM - Indicator inoperative - Instrument cluster Seat Belt Indicator Always On Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8909 Test 1 SYMPTOM SEAT BELT INDICATOR ALWAYS ON POSSIBLE CAUSES - ACM seat belt indicator command present - Instrument cluster Overhead Console Test 1 - 4 SYMPTOM REPAIRING CMTC DISPLAYS DOUBLE DASH (- - ) IN TEMP DISPLAY POSSIBLE CAUSES Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8910 - No response - PCI BUS - powertrain control module - CMTC BUS message failure - Compass mini-trip computer - Ambient temperature sensor - PCM ambient air temperature sensor DTC present - CMTC internal Left Cylinder Lock Switch Inoperative Test 1 - 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8911 Test 4 - 5 SYMPTOM LEFT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - left cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - left cylinder lock switch MUX short to voltage Remote Keyless Entry Inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8912 Test 1 - 4 Test 5 - 6 SYMPTOM REMOTE KEYLESS ENTRY INOPERATIVE POSSIBLE CAUSES - DTC present - SKREEM DTC present - Test transmitter with tester - RKE transmitter inoperative - RKE transmitter not programmed - SKREEM module - RKE inoperative - SKREEM module - RKE inoperative Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8913 Right Cylinder Lock Switch Inoperative Test 1 - 3 Test 4 - 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8914 SYMPTOM RIGHT CYLINDER LOCK SWITCH INOPERATIVE POSSIBLE CAUSES - DTC present - Body control module - right cylinder lock switch voltage low - Cylinder lock switch ground open - Cylinder lock switch MUX open - Cylinder lock switch open - Cylinder lock switch MUX short to voltage - Body control module - right cylinder lock switch MUX short to voltage Power Doors - Liftgate Test 1 - 4 SYMPTOM POWER LIFTGATE INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Power Doors - Sliding Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8915 Test 1 - 4 SYMPTOM POWER SLIDING DOOR INOPERATIVE POSSIBLE CAUSES - DTC's present - Module response - Intermittent problem - System tests Alarm Trips On Its Own Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8916 Test 1 - 4 SYMPTOM ALARM TRIPS ON ITS OWN POSSIBLE CAUSES - Last VTSS cause - Attempt to trip alarm - Intermittent condition Left Front Door Does Not Trip VTSS Test 1 SYMPTOM LEFT FRONT DOOR DOES NOT TRIP VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8917 POSSIBLE CAUSES - Body control module - Check DRBIII(R) for driver door ajar response Left Sliding Door Does Not Trip VTSS Test 1 SYMPTOM LEFT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Monitor DRBIII(R) for left sliding door ajar status - Body control module Right Front Door Does Not Trip VTSS Test 1 SYMPTOM RIGHT FRONT DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for passenger door ajar response - Body control module Right Sliding Door Does Not Trip VTSS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8918 Test 1 SYMPTOM RIGHT SLIDING DOOR DOES NOT TRIP VTSS POSSIBLE CAUSES - Check DRBIII(R) for right rear door ajar response - Body control module VTSS Will Not Arm Test 1 - 3 SYMPTOM VTSS WILL NOT ARM POSSIBLE CAUSES - Check the VTSS status - Check for BCM DTC's and VTSS arming inhibitors - Check for PCI BUS communication of instrument cluster and SKIM - Body control module Six Step Troubleshooting Procedure Diagnosis of the body system is done in six basic steps: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8919 - verification of complaint - verification of any related symptoms - symptom analysis - problem isolation - repair of isolated problem - verification of proper operation Road Testing ROAD TESTING A COMPLAINT VEHICLE Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. WARNING: REASSEMBLE ALL COMPONENTS BEFORE ROAD TESTING A VEHICLE. DO NOT TRY TO READ THE DRBIII(R) SCREEN OR OTHER TEST EQUIPMENT DURING A TEST DRIVE. DO NOT HANG THE DRBIII(R) OR OTHER TEST EQUIPMENT FROM THE REARVIEW MIRROR DURING A TEST DRIVE. HAVE AN ASSISTANT AVAILABLE TO OPERATE THE DRBIII(R) OR OTHER TEST EQUIPMENT. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Vehicle Preparation For Testing Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur. Glossary of Terms ABS antilock brake system ACT actuator APS adjustable pedals system ATC automatic temperature control BCM body control module BPS bladder pressure sensor BTS belt tension sensor CAB controller antilock brake CMTC compass/mini-trip computer CPA connector positive assurance DAB driver airbag DCHA diesel cabin heater assist (cabin heater) DLC data link connector DTC diagnostic trouble code DR driver EBL electric back lite (rear window defogger) ECM engine control module EVIC electronic vehicle information center FCM front control module GCC Gulf Coast Countries HE hall effect HFM hands free module HVAC heater ventilation, air conditioning IPM integrated power module KNB knee blocker airbag LDU lower drive unit LHD left hand drive MIC mechanical instrument cluster MTC manual temperature control MSMAPM memory seat/mirror/adjustable pedals module NAV navigation NGC next generation controller OBD on board diagnostics OCM occupant classification module OCS occupant classification system OCSVR occupant classification system verification required ODO odometer ORC occupant restraint controller PAB passenger airbag PASS passenger PCI Programmable Communication Interface (vehicle communication bus) PCM powertrain control module PDC power distribution center PLG power liftgate PLGM power liftgate module PSD power sliding door PSDM power sliding door module PWM pulse width modulated RHD Right Hand Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8920 RKE remote keyless entry RX receive SAB seat airbag SBS seat belt switch SBT seat belt tensioner SKREEM sentry key remote entry module SQUIB also called initiator (located inside airbag) SRS supplemental restraint system TCM transmission control module TPMS tire pressure monitor system TX transmit VFD vacuum fluorescent display VTSS vehicle theft security system DRB III Error Messages and Blank Screen DRBIII(R) ERROR MESSAGES Under normal operation, the DRBIII(R) will display one of only two error messages: user-requested WARM Boot or User-Requested COLD Boot. If the DRBIII(R) should display any other error message, record the entire display and call the STAR Center. This is a sample of such an error message display: ver:2.14 date: 26 Jul93 file: key_iff.cc date: Jul26 1993 line: 548 err: 0xi User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information. DRBIII(R) DOES NOT POWER UP (BLANK SCREEN) If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRBIII(R). Check for proper grounds at DLC cavities 4 and 5. If all connections are proper between the DRBIII(R) and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRBIII(R) may be the result or a faulty cable or vehicle wiring. DISPLAY IS NOT VISIBLE Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition. DRB III Safety Information WARNING: EXCEEDING THE LIMITS OF THE DRBIII(R) MULTIMETER IS DANGEROUS. READ ALL DRBIII(R) INSTRUCTIONS BEFORE USING THE MULTIMETER. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN PERSONAL INJURY OR DEATH. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8921 - Follow the vehicle manufacturer s service specifications at all times. - Do not use the DRBIII(R) if it has been damaged. - Do not use the test leads if the insulation is damaged or if metal is exposed. - To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. - Choose the proper range and functions for the measurement. Do not try voltage or current measurement that may exceed the rated capacity. - Do not exceed the limits shown in the table below: *Ohms cannot be measured if voltage is present. Ohms can be measured only in a non-powered circuit. - Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC. - Use caution when measuring voltage above 25v DC or 25v AC. - Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10 A. - When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. - When measuring current, connect the meter in series with the load. - Disconnect the live test lead before disconnecting the common test lead. - When using the meter function, keep the DRBIII(R) away from spark plug or coil wires to avoid measuring error from outside interference. KDB Lab Scope Pattern Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8922 PCI Bus Lab Scope Pattern Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 8923 Body Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lower instrument panel silencer. 3. Remove the knee blocker and reinforcement. 4. Disconnect the five wire connectors from the bottom of the Body Control Module (BCM). 5. Move bulkhead wiring aside. 6. Remove the screws holding the BCM to the bulkhead. 7. Remove the BCM from the mounting bracket. INSTALLATION 1. Install the BCM to the mounting bracket. 2. Install the screws holding the BCM to the bulkhead. 3. Connect the five wire connectors to the bottom of the Body Control Module (BCM). 4. Install the knee blocker and reinforcement. 5. Install the lower instrument panel silencer. 6. Connect the battery negative cable. 7. Verify proper operation of BCM and its functions. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 8924 Body Control Module: Tools and Equipment REQUIRED TOOLS AND EQUIPMENT DRBIII(R) (diagnostic read-out box) Jumper wires Ohmmeter Voltmeter Sentry Key Tester Test Light 8443 SRS Airbag System Load Tool 9077 Occupant Classification Seat Weights Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair Front Bumper Cover / Fascia: Service and Repair FRONT FASCIA REMOVAL 1. Release hood latch and open hood. 2. Remove the headlamp assemblies. 3. Hoist vehicle and support with safety stands. 4. Remove the five push pin fasteners attaching bottom of fascia/air dam to radiator closure panel. 5. Remove front wheels. 6. Remove front wheelhouse splash shields fasteners as necessary to gain access to bolts attaching front fascia to fender. Fig. 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Page 8930 Fig. 2 7. Remove the two bolts and two nuts attaching fascia to the front fenders (Fig. 1) and (Fig. 2). 8. Disconnect fog lamp wire connectors, if necessary. 9. Lower vehicle. 10. Remove two bolts attaching the upper grille support to the headlamp mounting panel at each side of the grille. 11. Remove bumper fascia from vehicle. INSTALLATION 1. Position front bumper fascia on vehicle (Fig. 1) and (Fig. 2). 2. Install the two bolts attaching fascia to headlamp mounting panel at each side of grille. 3. Hoist vehicle and support with safety stands. 4. Install the two bolts and two nuts attaching fascia to the front fenders. The fascia should be flush to fender. 5. Install front wheelhouse splash shields fasteners. 6. Install front wheels. 7. Connect fog lamp wire connectors, if necessary. 8. Install the five push pin fasteners attaching bottom of fascia to radiator closure panel. 9. Lower the vehicle. 10. Install the headlamp assemblies. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Service and Repair Front Bumper Reinforcement: Service and Repair FRONT BUMPER REINFORCEMENT REMOVAL 1. Remove front bumper fascia. Refer to Front Bumper Cover/Fascia. 2. Disconnect the solid state relay (SSR) for the cooling module wiring connector. If bumper reinforcement is being replaced, remove the solid state relay. 3. Support front bumper reinforcement on a suitable lifting device. Fig. 3 4. Remove the four nuts attaching front bumper reinforcement to frame rail (Fig. 3). 5. Remove front bumper reinforcement from vehicle. INSTALLATION NOTE: Check position of the arrows molded into the foam for correct orientation. 1. Support front bumper reinforcement using a suitable lifting device and lift into position. 2. Install the four nuts attaching reinforcement to frame rails. Tighten nuts to 54 N.m (40 ft.lbs.) torque. 3. Connect the solid state relay (SSR) wiring connector. If bumper reinforcement was replaced, install the solid state relay onto the bumper reinforcement. 4. Install front fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Fascia Rear Bumper Cover / Fascia: Service and Repair Rear Fascia REAR FASCIA REMOVAL 1. Open liftgate. 2. Remove attaching screw from upper fascia to the liftgate tower, right side and left side. 3. Hoist and support vehicle with safety stands. Fig. 4 4. Disconnect rear park assist wire connector (Fig. 4), if equipped. Fig. 5 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Fascia > Page 8939 Fig. 6 5. Remove the three screws attaching rear fascia to rear fascia brackets on right side and left side (Fig. 5) and (Fig. 6). 6. Remove the four plastic push pin attaching bottom of rear fascia to fascia support. 7. Remove rear fascia from vehicle by lifting sides of fascia up and outboard to release from rear fascia brackets. Fig. 7 8. Remove park assist sensor (Fig. 7), if necessary. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Fascia > Page 8940 Fig. 8 1. Install park assist sensor(s) (Fig. 8), if necessary. 2. Hoist and support vehicle with safety stands. Fig. 9 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Fascia > Page 8941 Fig. 10 3. Position rear fascia on vehicle (Fig. 9) and (Fig. 10). Fig. 11 4. Connect the rear park assist wire connector (Fig. 11), if equipped. 5. Engage front edge of fascia under the liftgate tower. Install screw in liftgate tower right side and left side. 6. Engage sides of fascia to top and front edge of the rear fascia brackets. NOTE: Verify fascia is still engaged under the liftgate. Ensure acceptable and consistent gap between liftgate and fascia. 7. Install three screws attaching rear fascia to rear fascia brackets, right side and left side. 8. Install the four plastic push pins attaching bottom of rear fascia to fascia support. 9. Lower vehicle. 10. Install the two screws attaching the upper fascia to the fascia support. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Fascia > Page 8942 Rear Bumper Cover / Fascia: Service and Repair Rear Fascia Scuff Pad REAR FASCIA - SCUFF PAD REMOVAL The scuff pad may not be salvageable during the removal process. The scuff pad should be replaced if damaged or broken. Check availability before servicing. The scuff pad serviceability is improved if the rear fascia is to be removed for service. NOTE: If the rear fascia is to be removed for other service issues or If the scuff pad is to be reused use the steps below. 1. Remove rear bumper fascia. Refer to Rear Bumper. Fig. 13 2. Using a trim stick, pry up the rear edge of the scuff pad while squeezing the rear locking tabs from underneath the fascia to release the rear edge of scuff pad from the rear bumper fascia. Pull the scuff pad up and squeeze the remaining tabs to release the remaining of the scuff pad. (Fig. 13). NOTE: If the rear fascia is to not to be removed for other service issues use the step below. 3. Using a trim stick, pry up the rear edge of the scuff pad to release tabs from the rear bumper fascia and pull scuff pad to release the forward tabs (Fig. 13). INSTALLATION 1. Verify that there are fifteen slots in the fascia. 2. Place scuff pad in position (Fig. 13). 3. Align and insert the center forward tab. 4. Align the remaining tabs and press into the slots, starting in the center and working outboard. 5. Assure all tabs are fully engaged into the fascia. 6. If rear bumper fascia has been removed install. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Service and Repair Rear Bumper Reinforcement: Service and Repair REAR BUMPER REINFORCEMENT REMOVAL 1. Remove rear bumper fascia. Refer to Rear Bumper Cover/Fascia. 2. Support rear bumper reinforcement on a suitable lifting device. Fig. 12 3. Remove the four nuts attaching rear bumper reinforcement to frame rail extensions (Fig. 12). 4. Remove rear bumper reinforcement from vehicle. INSTALLATION 1. Support rear bumper reinforcement using a suitable lifting device to lift into position. 2. Position rear bumper reinforcement on vehicle. 3. Install the four nuts attaching rear bumper reinforcement to frame rail extensions and tighten to 27 N.m (20 ft.lbs.) torque (Fig. 12). 4. Install rear bumper fascia. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair REAR QUARTER PANEL / FENDER AIR EXHAUSTER DESCRIPTION Air exhausters, designed to conform to the body structure, allow air entering at the front of the vehicle to flow out the back. By reducing air pressure within the vehicle, the exhausters also reduce blower noise at any given air flow level compared to operating without them and help reduce door closing effort. They are located in the lower rear corners of the body. REMOVAL SHORT WHEELBASE 1. Remove the rear fascia from the body. Refer to Rear Bumper. Fig. 21 2. Using a trim stick or another suitable wide flat bladed tool, carefully pry the air exhauster away from the opening in the lower aperture panel until the snap features release (Fig. 21). 3. Remove the air exhauster from the hole in the lower aperture panel. LONG WHEELBASE NOTE: Models with the optional rear heater and air conditioner do not have an air exhauster on the right side of the vehicle, but have a plastic plug installed in the right lower aperture panel. This plug is removed using the same procedure used to remove the air exhauster from the short wheelbase model. 1. Remove the quarter trim panel from the inside of the left or right quarter inner panel. Refer to Trim Panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Service and Repair > Page 8949 Fig. 22 2. Using a trim stick or another suitable wide flat bladed tool, carefully pry the air exhauster away from the opening in the lower aperture panel until the snap features release (Fig. 22). 3. Remove the air exhauster from the hole in the lower aperture panel. INSTALLATION SHORT WHEELBASE 1. Position the air exhauster to the hole in the lower aperture panel (Fig. 21). 2. Using hand pressure, press the air exhauster into the opening in the lower aperture panel until the snap features are fully engaged. 3. Reinstall the rear fascia onto the body. LONG WHEELBASE NOTE: Models with the optional rear heater and air conditioner do not have an air exhauster on the right side of the vehicle, but have a plastic plug installed in the right lower aperture panel. This plug is installed using the same procedure used to install the air exhauster onto the short wheelbase model. 1. Position the air exhauster to the hole in the lower aperture panel (Fig. 22). 2. Using hand pressure, press the air exhauster into the opening in the lower aperture panel until the snap features are fully engaged. 3. Reinstall the quarter trim panel onto the inside of the left or right quarter inner panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE REMOVAL 1. Remove wiper arms. Fig. 6 2. Remove four (4) screws securing cowl cover to wiper module (Fig. 6). 3. Disengage quarter turn fasteners at outboard ends of cowl grill from body. 4. Release hood latch and open hood. CAUTION: To prevent hood scratching of cowl grille before removal, cover outboard exterior ends of cowl grille with masking tape or equivalent method. NOTE: Do not over bend cowl grille during removal. Bend cowl grille just enough to clear top of wiper pivot shaft and bottom rear corner of hood. 5. Remove cowl grill by raising above driver side wiper pivot shaft and swinging away towards engine compartment. The cowl grille will need to be bent on outboard end to clear simultaneously top of wiper pivot shaft and bottom corner of hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 8954 Fig. 7 6. Close hood. Do not latch. Remove outboard screws. (Fig. 7). 7. Disconnect washer hose in line connector. 8. Disconnect washer hose and grommet from hole in wiper module and pull out. 9. Remove cowl grille by raising over opposite wiper pivot shaft and removing away from vehicle. 10. Remove cowl cover from vehicle. INSTALLATION 1. Reverse removal procedure. 2. When installing cowl cover over wiper module, make sure fore aft locator on the underside of cowl grill seat into the locator grooves on top of wiper module. 3. Start all cowl grille mounting screws by hand before torquing to specifications. 4. Assure washer hose is properly routed and not pinched. 5. Center cowl grille to body and windshield. 6. Assure "arrow" indicator head of quarter turn fasteners is pointing toward windshield. 7. Tighten screw to 1.2 N.m (11 in.lbs.) torque. 8. Install the wiper arms. 9. Check for proper spray pattern from washer nozzles. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Door Stop > Component Information > Service and Repair > Sliding Door Stop Bumper Bezel Door Stop: Service and Repair Sliding Door Stop Bumper Bezel SLIDING DOOR STOP BUMPER BEZEL REMOVAL 1. Using a trim stick (C-4755), disengage clips attaching door stop bumper bezel to the door trim panel. Fig. 1 2. Remove bezel from vehicle (Fig. 1). INSTALLATION 1. Place door stop bumper bezel into position (Fig. 1) 2. Engage clips attaching door stop bumper bezel to the door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Door Stop > Component Information > Service and Repair > Sliding Door Stop Bumper Bezel > Page 8961 Door Stop: Service and Repair Stop Bumper STOP BUMPER REMOVAL 1. Remove door stop bumper bezel. Fig. 1 2. Loosen screws attaching rear of stop bumper to door inner panel (Fig. 1). 3. Remove screw attaching front of door stop bumper to door inner panel. 4. Remove door stop bumper from vehicle. INSTALLATION 1. Place stop bumper in position on vehicle. 2. Install screw attaching front of stop bumper to door inner panel (Fig. 1). 3. Tighten screws attaching rear of stop bumper to door inner panel. 4. Install door stop bumper bezel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Roll door glass up. 2. Remove the watershield as necessary to gain access to the outside door handle. Refer to Front Door Panel. 3. Through access hole at rear of inner door panel, disconnect Vehicle Theft Security System (VTSS) switch connector from door harness, if equipped. 4. Disengage push in fasteners attaching VTSS switch harness to inner door reinforcement bar, if equipped. Fig. 21 5. Disengage clip holding door latch linkage to door latch (Fig. 21). 6. Remove latch linkage from latch. 7. Disengage clip holding door lock linkage to door latch. 8. Remove lock linkage from latch. 9. Remove nuts holding outside door handle to door outer panel. 10. Remove outside door handle from vehicle. INSTALLATION If outside door handle replacement is necessary, transfer lock cylinder from the original handle to the new one. 1. Place outside door handle in position on vehicle. 2. Install nuts attaching outside door handle to door outer panel (Fig. 21). Tighten nuts to 6 N.m (50 in.lbs.). 3. Insert lock linkage into door latch. 4. Engage clip to hold door lock linkage to latch. 5. Insert latch linkage into door latch. 6. Engage clip to hold door latch linkage to latch. 7. Install push-in fasteners to hold VTSS switch harness to inner door reinforcement bar, if equipped. 8. Connect VTSS switch connector into door harness, if equipped. 9. Verify door latch operation. 10. Install sound shield and door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Handle Switch > System Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair Front Door Hinge: Service and Repair HINGE REMOVAL 1. Release front door latch and open door. 2. Mark hinge foot print on both door and pillar to aid when installing door. 3. Support door on suitable lifting device. 4. Remove bolts attaching front door to door hinge. 5. Remove bolts attaching hinge to pillar. 6. Remove door hinge from vehicle. INSTALLATION CAUTION: When installing a new hinge, make sure that the head of each hinge pin is fully seated into the door hinge. Also, remove the plastic shipping clip and replace it with the correct metal retaining clip once the hinge pin is seated. 1. Paint hinge prior to installation, if necessary. 2. Position door to vehicle. Verify net pierce nubbin is engaged if reusing original hinges. Applies to body half of hinge only. 3. Install bolts attaching hinge to pillar. Tighten bolts to 34 N.m (25 ft.lbs.). 4. Install bolts attaching front door to door hinge. Tighten bolts to 34 N.m (25 ft.lbs.). 5. Align door to achieve equal spacing to surrounding body panels. Panels should be flush across all gaps. 6. Verify door alignment and operation. Adjust as necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair Front Door Latch: Service and Repair LATCH REMOVAL 1. Roll door glass up. 2. Remove front door trim panel. 3. Remove watershield as necessary to gain access to the outside door handle. 4. Through access hole at rear of inner door panel, disconnect wire connector from power door lock motor, if equipped. Fig. 18 5. Disengage clips holding linkage to door latch (Fig. 18). 6. Remove linkages from door latch. Fig. 19 7. Remove screws attaching door latch to door end frame (Fig. 19). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Page 8976 8. Remove door latch from door. INSTALLATION NOTE: The screws attaching the door latch to the door end frame have nylon patches on the threads. All screws must be replaced when the latch has been removed. 1. Insert inside handle latch link to door latch and engage clip (Fig. 18). 2. Place door latch in position on door end frame. 3. Install screws attaching door latch to door end frame. Tighten screws to 10 N.m (90 in.lbs.) torque (Fig. 19). 4. Insert other linkages to door latch and engage clips. 5. Connect wire connector into power door lock motor, if equipped. 6. Insert a hex wrench through the elongated hole located in the door shut face above the latch. 7. Loosen alien head screw. 8. Pull outward on the outside door handle and release. 9. Tighten alien head screw. 10. Verify door latch and power door lock operation. 11. Install watershield and front door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System Information > Service and Repair Front Door Limiter: Service and Repair CHECK STRAP REMOVAL 1. Remove front door trim panel. 2. Remove front door watershield. Refer to Front Door Panel. 3. Remove front door speaker, if equipped. Fig. 2 4. Remove bolts attaching door check strap to A-pillar (Fig. 2). Fig. 3 5. Remove nuts attaching check strap to door end frame (Fig. 3). 6. Remove check strap from door through speaker hole. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Limiter > System Information > Service and Repair > Page 8980 Fig. 4 1. Position check strap on door through speaker hole (Fig. 4). 2. Install nuts to attach check strap to door end frame. Tighten nuts to 11 N.m (90 in.lbs.) torque. Fig. 5 3. Install bolts to attach check strap to A-pillar. Tighten bolts to 12 N.m (105 in.lbs.) torque (Fig. 5). 4. Install door speaker, if equipped. 5. Install front door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures Front Door Panel: Procedures Trim Panel REMOVAL 1. Remove the plug and remove screw attaching door pull cup to inner door panel. 2. Remove switch bezel and disconnect power window/memory switch. 3. Remove screws attaching trim panel to door from below map pocket. 4. If equipped, remove window crank. 5. Remove screw holding door trim to door panel from behind inside latch release handle. 6. Disengage clips attaching door trim to door frame around perimeter of panel. 7. Lift trim panel upward to disengage flange from inner belt molding at top of door. 8. Tilt top of trim panel away from door to gain access to latch linkage. Inside Door Handle Linkage 9. Disengage clip attaching linkage rod to inside latch release handle. 10. Separate linkage rod from latch handle. 11. Disconnect the power door switch, courtesy lamp electrical connectors. 12. Remove front door trim panel from vehicle. INSTALLATION 1. Hold top of trim panel away from door to gain access to latch linkage. 2. Place linkage rod in position on latch handle. 3. Engage clip to hold linkage rod to inside latch release handle. 4. Place front door trim panel in position on door. 5. Install trim panel into inner belt molding at top of door. 6. Install clips to attach door trim to door frame around perimeter of panel. 7. If equipped, install screw to attach door trim to door panel behind inside latch release handle. 8. If equipped, connect power switch into wire connector. 9. Place power accessary switch in position on door trim. 10. Connect wire connector into memory seat/mirror switch and install switch into trim panel. 11. Install screws to attach accessary switch panel to door trim. 12. Install screw cover into switch panel. 13. If equipped, install window crank. 14. If equipped, install screws to attach trim panel to door inside map pocket. 15. If equipped, install screw to attach door pull cup to inner door panel. 16. If equipped, install screws to attach door assist handle to inner door panel. 17. Connect wire connector into courtesy lamp. 18. Install lamp in door trim. 19. Install switch bezel. Watershield Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 8985 WATERSHIELD REMOVAL 1. Remove door trim panel. 2. Remove the front door speaker. 3. Peel watershield away from adhesive around perimeter of inner door panel. INSTALLATION 1. Insure that enough adhesive remains to securely retain the water dam. Replace as necessary. 2. Place the shield into position and press securely to adhesive making sure to properly route wiring and linkages. 3. Install the front door speaker. 4. Install door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 8986 Front Door Panel: Removal and Replacement Watershield WATERSHIELD REMOVAL 1. Remove door trim panel. 2. Remove the front door speaker. 3. Peel watershield away from adhesive around perimeter of inner door panel. INSTALLATION 1. Insure that enough adhesive remains to securely retain the water dam. Replace as necessary. 2. Place the shield into position and press securely to adhesive making sure to properly route wiring and linkages. 3. Install the front door speaker. 4. Install door trim panel. Trim Panel TRIM PANEL REMOVAL 1. Remove the plug and remove screw attaching door pull cup to inner door panel. 2. Remove switch bezel and disconnect power window/memory switch. 3. Remove screws attaching trim panel to door from below map pocket. 4. If equipped, remove window crank. 5. Remove screw holding door trim to door panel from behind inside latch release handle. 6. Disengage clips attaching door trim to door frame around perimeter of panel. 7. Lift trim panel upward to disengage flange from inner belt molding at top of door. 8. Tilt top of trim panel away from door to gain access to latch linkage. Fig. 22 9. Disengage clip attaching linkage rod to inside latch release handle (Fig. 22). 10. Separate linkage rod from latch handle. 11. Disconnect the power door switch, courtesy lamp electrical connectors. 12. Remove front door trim panel from vehicle. INSTALLATION 1. Hold top of trim panel away from door to gain access to latch linkage. 2. Place linkage rod in position on latch handle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Procedures > Page 8987 3. Engage clip to hold linkage rod to inside latch release handle. 4. Place front door trim panel in position on door. 5. Install trim panel into inner belt molding at top of door. 6. Install clips to attach door trim to door frame around perimeter of panel. 7. If equipped, install screw to attach door trim to door panel behind inside latch release handle. 8. If equipped, connect power switch into wire connector. 9. Place power accessary switch in position on door trim. 10. Connect wire connector into memory seat/mirror switch and install switch into trim panel. 11. Install screws to attach accessary switch panel to door trim. 12. Install screw cover into switch panel. 13. If equipped, install window crank. 14. If equipped, install screws to attach trim panel to door inside map pocket. 15. If equipped, install screw to attach door pull cup to inner door panel. 16. If equipped, install screws to attach door assist handle to inner door panel. 17. Connect wire connector into courtesy lamp. 18. Install lamp in door trim. 19. Install switch bezel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair Front Door Striker: Service and Repair LATCH STRIKER REMOVAL 1. Mark outline of door striker on B-pillar to aid in installation. Fig. 20 2. Remove screws attaching door latch striker to B-pillar (Fig. 20). 3. Remove door latch striker from vehicle. 4. Retrieve any shims found between latch striker and B-pillar. INSTALLATION 1. Position latch striker and any shims retrieved on vehicle. 2. Loosely install screws attaching latch striker to B-pillar. 3. Align latch striker to outline on B-pillar made previously. 4. Tighten fasteners to 28 N.m (21 ft.lbs.) torque. 5. Verify door fit and operation. Adjust latch striker as necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair Front Door Weatherstrip: Service and Repair FRONT DOOR WEATHERSTRIP REMOVAL 1. Open front door. Fig. 2 2. Using fork tool (C-4829), remove push pin fasteners attaching front door weatherstrip to end frames and bottom of door (Fig. 2). 3. Pull weatherstrip from retaining channel around window frame. 4. Remove weatherstrip from vehicle. INSTALLATION 1. Position weatherstrip on door. 2. Install push pin fasteners attaching front door weatherstrip to end frames and bottom of door (Fig. 2). 3. Install weatherstrip into retaining channel around window frame. 4. Close front door. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Molding FRONT DOOR OUTER BELT MOLDING REMOVAL 1. Remove the side view mirror. 2. Remove door trim panel. 3. Roll door glass down. Fig. 1 4. Using a hook tool, disengage interlocking lip at the base of the inward edge of the belt molding (Fig. 1). 5. Remove belt molding from door. INSTALLATION 1. Place belt molding in position on door (Fig. 1). NOTE: Make sure end of applique is against outer belt. 2. Engage interlocking lip at the base of the inward edge of the belt molding on door panel. 3. Install door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 8999 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove door frame closeout moldings. 2. Pull weatherstrip from glass run channel at rear of door frame, working from the bottom to the top. 3. Disengage clip attaching weatherstrip to door frame. Fig. 1 4. Pull weatherstrip from lip along top of door frame (Fig. 1). 5. Remove door trim panel. 6. Remove door speaker, if equipped. 7. Remove watershed as necessary to gain access to screw attaching front lower corner of glass run weatherstrip to inner door panel. 8. Remove screw attaching glass run weatherstrip to inner door panel. 9. Remove inner belt weatherstrip. 10. Pull weatherstrip from front glass run channel. 11. Remove glass run weatherstrip from vehicle. INSTALLATION 1. Position glass run weatherstrip on vehicle (Fig.1). 2. Insert A-pillar section of the glass run into door through belt line and lower to bottom of door using molded corners as a guide. NOTE: Care must be taken not to damage the medal bracket when installing through the belt opening. 3. Locate the top corner portion of the B-pillar glass run section onto the roll frame and slide it up until the part bottoms out on the header portion of the roll frame. NOTE: Do not JAM the corner into place. 4. Install the entire B-pillar glass run onto roll frame. 5. Working from the B-pillar forward install the first eight to twelve inches of the header glass run onto the roll frame. NOTE: Use care not to push or pull the header section and the molded corner out of location. 6. Install fully the entire A-pillar glass run section by indexing the molded corner detail into the roll frame. Slide the glass run up the A-pillar until Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 9000 the rubber molded joint just touches the roll frame. 7. Verify that the tertiary seal is on the correct side of the roll frame prior to seating the glass run fully onto the frame. Verify the glass runs is fully seated for the header, and A-pillar and B-pillar 8. Install screw attaching glass run weatherstrip to inner door panel. 9. Install inner belt weatherstrip. 10. Install watershed. 11. Push weatherstrip groove onto lip along top of door frame. 12. Engage clip into slot in door frame. 13. Push weatherstrip into channel at rear of door frame, working from the top to bottom. 14. Install door frame closeout moldings. 15. Install door speaker, if equipped. 16. Install door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 9001 Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Molding FRONT DOOR INNER BELT MOLDING REMOVAL 1. Remove door trim panel. 2. Peel upper corner seals away form inner belt molding to clear removal path. Fig. 1 3. Pull inner belt molding upward to disengage retaining channel in bottom of molding from door panel flange (Fig. 1). 4. Remove inner belt molding from vehicle. INSTALLATION 1. Place inner belt molding in position on door (Fig. 1). 2. Push inner belt molding downward to engage retaining channel onto door panel flange. 3. Install upper corner seals in proper location. 4. Install door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair REMOVAL The window motor is incorporated into the window regulator assembly. If the window motor requires replacement, the window regulator must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Manual Front Door Window Regulator: Service and Repair Manual REMOVAL 1. Remove watershield. 2. Remove inner belt molding. 3. Remove door glass. Front Door Manual Window 4. Loosen screws attaching front and rear window guide rails to inner door panel. 5. Remove screw heads on guide rails from key hole slots in inner door panel. 6. Loosen screws attaching regulator to inner door panel. 7. Remove regulator from inner door panel. 8. Extract rear guide rail through inner door panel rear access hole. 9. Extract front guide rail through front access hole. INSTALLATION Front Door Manual Window Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Manual > Page 9009 1. Insert front guide rail through front access hole. 2. Insert rear guide rail through rear access hole. 3. Place window regulator in position on inner door panel. 4. Place screw heads on guide rails in position through key hole slots in inner door panel. 5. Tighten screws to attach front and rear guide rails to inner door panel to 8.5 -1 0.7 Nm (75 -9 5 in. IDS.). Tighten using the sequence. 6. Tighten screws to attach regulator to inner door panel to 2.8 Nm (25 in. IDS.). 7. Install door glass. 8. Verify door glass alignment and operation. 9. Install inner belt molding. 10. Install watershield. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Manual > Page 9010 Front Door Window Regulator: Service and Repair Power REMOVAL 1. Remove watershield. 2. Remove inner belt molding. 3. Remove door glass. 4. Disconnect wire connector from power window motor. Front Door Power Window 5. Loosen screws attaching front and rear window guide rails to inner door panel. 6. Remove screw heads on guide rails from key hole slots in inner door panel. 7. Loosen screws attaching motor/housing to inner door panel. Front Door Power Window 8. Remove regulator from inner door panel. 9. Extract rear guide rail through inner door panel rear access hole. 10. Extract front guide rail through front access hole. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Manual > Page 9011 Front Door Power Window 1. Insert front guide rail through front access hole. 2. Insert rear guide rail through rear access hole. 3. Place window regulator in position on inner door panel. 4. Place screw heads on guide rails in position through key hole slots in inner door panel. 5. Tighten screws to attach front and rear guide rails to inner door panel to 8.5 - 10.7 Nm (75 - 95 in. IDS.). Tighten using the sequence. Front Door Power Window 6. Tighten screws to attach motor/housing to inner door panel to 2.8 Nm (25 in. lbs.). 7. Connect wire connector into power window motor. 8. Install door glass. 9. Verify door glass alignment and operation. 10. Install inner belt molding. 11. Install watershield. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Center Sliding Door Roller > Component Information > Service and Repair Center Sliding Door Roller: Service and Repair CENTER HINGE REMOVAL NOTE: For power sliding door procedures. 1. Open sliding door to the mid point of its travel. 2. Support sliding door on a suitable lifting device. 3. Mark outline of center hinge of inner door panel to aid installation. 4. Remove bolts attaching center hinge to sliding door. 5. Remove center hinge from sliding door. 6. Roll center hinge to rear of roller channel. 7. Remove center hinge from vehicle. INSTALLATION NOTE: For power sliding door procedures. NOTE: Center hinge has an adjustable bolt for up/down alignment. 1. Place center hinge in position on vehicle. 2. Roll center hinge forward in roller channel. 3. Place center hinge in position on sliding door and align marks. 4. Install bolts attaching center hinge to sliding door. 5. Verify sliding door alignment and operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Lower Sliding Door Rail > Component Information > Description and Operation Lower Sliding Door Rail: Description and Operation Rack Access Hole Locations The door track and rack assembly provides a mating rack gear for the lower drive unit to engage. The track also accepts the lower hinge rollers, which helps support the weight of the sliding door as well as providing a smooth surface for the hinge rollers to move upon. The lower door track is a replaceable component. With the start of a power sliding door open cycle, the door motor drives the flex drive assembly. The flex drive assembly drives the lower drive unit. A metal drive gear which is part of the lower drive unit, meshes with the door track rack teeth and moves the sliding door into the full open position. The same operation repeats itself, during a power close cycle only the system rotates in the opposite direction. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Lower Sliding Door Rail > Component Information > Description and Operation > Page 9019 Lower Sliding Door Rail: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the side door sill plate. 3. Remove the hold-open striker. Supporting Sliding Door 4. Position a floor jack, with a block of wood under the leading edge of the side door to support it. 5. Remove the lower hinge assembly from the door. 6. Position the wire harness assembly out of door opening, this will allow sufficient room to remove the door track. Lower Track Retaining Nuts 7. Pull back the sealing patches and remove the lower track retaining nuts. 8. Carefully remove the lower sliding door track from the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Lower Sliding Door Rail > Component Information > Description and Operation > Page 9020 INSTALLATION 1. Carefully position the lower sliding door track in the vehicle. Lower Track Retaining Nuts 2. Install the lower track retaining nuts and install the sealing patches. Torque the nuts to 8 Nm (70 in. lbs). 3. Install the lower hinge assembly on the door. NOTE: Take care to locate the lower hinge assembly on the door in its original position (ie. match screw washer with rings left on hinge). Adjust door fit if required. 4. Remove the floor jack. 5. Install the hold-open striker. 6. Install the side door sill plate. 7. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Lower Sliding Door Roller > Component Information > Description and Operation Lower Sliding Door Roller: Description and Operation Lower Drive Unit The lower drive unit is located on the power sliding door lower hinge assembly. This drive unit is used to transfer the rotation of the flex drive assembly into longitudinal movement via the drive unit gear and door track rack teeth. During a power open or close cycle, the power drive unit is driven by the flex drive assembly. The lower drive units main gear engages the lower door tracks rack teeth, this moves the power sliding door assembly accordingly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Lower Sliding Door Roller > Component Information > Service and Repair > Procedures Lower Sliding Door Roller: Procedures REMOVAL 1. Disconnect and isolate the battery negative cable. Sliding Door Lower Hinge Assembly 2. Open the appropriate sliding door and remove the lower drive unit cover retaining screws. Lower Drive Unit Retaining Fasteners 3. Remove the lower drive unit retaining fasteners. 4. Disconnect the flex drive assembly from the lower drive unit. Expand the flex drive collar until the lower drive unit can be pulled straight off. 5. Remove the lower drive unit from the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Lower Sliding Door Roller > Component Information > Service and Repair > Procedures > Page 9026 INSTALLATION 1. Position the lower drive unit near the lower hinge. Lower Drive Unit 2. Connect the flex drive assembly on the lower drive unit. Push the flex drive collar straight on until the it snaps in place. It may be necessary to rotate the drive unit slightly until the flex drive seats in place. Lower Drive Unit Retaining Fasteners 3. Install the lower drive unit retaining fasteners. Torque the larger alien headed center stud to 9 Nm (80 in. lbs.). Torque the smaller screw to 3 Nm (28 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Lower Sliding Door Roller > Component Information > Service and Repair > Procedures > Page 9027 Sliding Door Lower Hinge Assembly 4. Install the lower drive unit cover and retaining screws. 5. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Lower Sliding Door Roller > Component Information > Service and Repair > Procedures > Page 9028 Lower Sliding Door Roller: Removal and Replacement LOWER HINGE REMOVAL NOTE: For power sliding door procedures. 1. Open sliding door. Fig. 8 2. Mark outline of roller arm on sliding door to aid installation (Fig. 8). 3. Remove sliding door sill plate. Refer to Trim Panel. 4. Remove screws attaching open latch to lower roller arm. 5. Remove open latch from lower arm. 6. Support sliding door on a suitable lifting device with a padded upper surface. The door must be moveable with lifting device in place. 7. Remove hold open latch striker. 8. Remove bolts attaching lower roller arm to sliding door. 9. Remove roller arm from sliding door. 10. Disengage roller arm from lower channel. 11. Remove roller arm from vehicle. INSTALLATION NOTE: For power sliding door procedures. 1. Place roller arm into position (Fig. 8). 2. Engage roller arm to lower channel. 3. Install roller arm to sliding door. 4. Install bolts attaching lower roller arm to sliding door. 5. Install hold open latch striker. 6. Install screws attaching open latch to lower roller arm. 7. Install sliding door sill plate. 8. Check sliding door for proper operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Module > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Module > Component Information > Locations > Component Locations > Page 9033 Power Sliding Door Module: Connector Locations Right Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Module > Component Information > Locations > Component Locations > Page 9034 Liftgate And Sliding Door Modules Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Module > Component Information > Locations > Page 9035 Power Sliding Door Module: Diagrams Left Sliding Door Control Module C1 (Power Sliding Door) Left Sliding Door Control Module C2 (Power Sliding Door) Right Sliding Door Control Module C1 (power Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Module > Component Information > Locations > Page 9036 Right Sliding Door Control Module C2 (power Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Module > Component Information > Locations > Page 9037 Power Sliding Door Module: Description and Operation Power Side Door Components Vehicles equipped with a power sliding door system utilize a sliding door control module. The sliding door control module is located behind the sliding door trim panel in the center of the door, just above the sliding door motor. This module controls the operation of the door through the Programmable Communication Interface (PCI) data bus circuit and the Body Control Module (BCM). The sliding door control module contains software technology which enables it to detect resistance to door travel and to reverse door travel in order to avoid damage to the door or to avoid possible personal injury if the obstruction is a person. This feature functions in both the opening and closing cycles. If the power sliding door system develops any problems the control module will store and recall Diagnostic Trouble Codes (DTC). The use of a diagnostic scan tool, such as the DRB III(R) is required to read and troubleshoot these trouble codes. The sliding door control module can be reflashed if necessary. Refer to the latest Technical Service Bulletin (TSB) Information for any updates. The power door control module is a replaceable component and cannot be repaired, if found to be faulty it must be replaced. The power sliding door control module serves as the main computer for the power sliding door system. All power door functions are processed through the power sliding door control module and/or the vehicles Body Control Module (BCM). At the start of a power open command, a signal is sent to the BCM and then to the power sliding door control module via the Programmable Communication Interface (PCI) data bus circuit. This signal, generated by any of the power door command switches, tells the power sliding door control module to activate a power latch release, engage the clutch assembly and drive the door into the full open position. If an obstacle is felt during this power open cycle, the module will reverse direction and close the door. This process is also enabled during a power close cycle. This process will repeat three times, and if a fourth obstacle is detected, the door will go into full manual mode. Once the full open position is obtained, a hold open latch assembly mounted full open switch tells the power sliding door control module that the door has reached the full open position. If the power sliding door system develops any problems the power sliding door control module will store and recall Diagnostic Trouble Codes (DTC). The use of a diagnostic scan tool, such as the DRB III(R) is required to read and troubleshoot these trouble codes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Module > Component Information > Locations > Page 9038 Power Sliding Door Module: Testing and Inspection Any diagnosis of the power sliding door system should begin with the use of the DRB III(R) diagnostic tool. Inspect the related wiring harness connectors for broken, bent, pushed out, or corroded terminals. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Module > Component Information > Locations > Page 9039 Power Sliding Door Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the appropriate door trim panel from the vehicle. 3. Remove the weather shield. 4. Disconnect the power door control module electrical connectors. Slide the red locking tab out (away from module) and depress connector retaining tab, while pulling straight apart. Power Side Door Components 5. Remove the control module retaining screw. 6. Remove the module from the vehicle. INSTALLATION 1. Position the sliding door control module and install the retaining screw. 2. Connect the electrical connectors. Slide the locking tab into the locked position. 3. Install the weather shield. 4. Install the appropriate door trim panel on the vehicle. 5. Connect the battery negative cable. 6. Using an appropriate scan tool, check and erase any power door control module diagnostic trouble codes. 7. Verify power door system operation. Cycle the power door through one complete open and close cycle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Motor > Component Information > Technical Service Bulletins > Customer Interest for Power Sliding Door Motor: > 23-007-10 > Jun > 10 > Body - Hard To Manually Open/Close Side Sliding Doors Power Sliding Door Motor: Customer Interest Body - Hard To Manually Open/Close Side Sliding Doors NUMBER: 23-007-10 GROUP: Body DATE: June 9, 2010 SUBJECT: Excessive Effort In Opening Or Closing The Sliding Door Manually OVERVIEW: This Bulletin provides Diagnostic steps to determine if the sliding door motor is adding resistance to the mechanical operation of the sliding door. MODELS: 2001 - 2007 (RS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Customer may complain that the sliding door is hard or difficult to operate in the manual mode. DIAGNOSIS: 1. Confirm customer complaint that the door is difficult to operate manually. 2. Remove door panel. Refer to the detailed procedures available in DealerConnect > TechConnect under Service Info > 23 Body > Doors - Sliding > Panel, Door Trim > Removal/Install. 3. Remove "E" clip from the drive cable going into the motor. 4. Remove drive cable from motor 5. Manually slide to door back and forth. Does the door move easily? a. YES >>> Proceed to the Repair Procedure. b. NO >>> This bulletin does not apply. Further diagnosis is required. PARTS REQUIRED: REPAIR PROCEDURE: 1. With the Door Panel already removed and "E" clip and cable disconnected, remove the 2 bolts holding the drive motor to the drive unit. 2. Replace sliding door motor. 3. Reinstall cable and "E clip. 4. Install door panel. Refer to the detailed procedures available in DealerConnect > TechConnect under Service Info> 23 Body > Doors - Sliding > Panel, Door Trim > Removal/Install. 5. Preform Power Door Learn Cycle. 6. Test and return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Motor > Component Information > Technical Service Bulletins > Customer Interest for Power Sliding Door Motor: > 23-007-10 > Jun > 10 > Body - Hard To Manually Open/Close Side Sliding Doors > Page 9048 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Sliding Door Motor: > 23-007-10 > Jun > 10 > Body - Hard To Manually Open/Close Side Sliding Doors Power Sliding Door Motor: All Technical Service Bulletins Body - Hard To Manually Open/Close Side Sliding Doors NUMBER: 23-007-10 GROUP: Body DATE: June 9, 2010 SUBJECT: Excessive Effort In Opening Or Closing The Sliding Door Manually OVERVIEW: This Bulletin provides Diagnostic steps to determine if the sliding door motor is adding resistance to the mechanical operation of the sliding door. MODELS: 2001 - 2007 (RS) Town & Country/Caravan/Voyager SYMPTOM/CONDITION: Customer may complain that the sliding door is hard or difficult to operate in the manual mode. DIAGNOSIS: 1. Confirm customer complaint that the door is difficult to operate manually. 2. Remove door panel. Refer to the detailed procedures available in DealerConnect > TechConnect under Service Info > 23 Body > Doors - Sliding > Panel, Door Trim > Removal/Install. 3. Remove "E" clip from the drive cable going into the motor. 4. Remove drive cable from motor 5. Manually slide to door back and forth. Does the door move easily? a. YES >>> Proceed to the Repair Procedure. b. NO >>> This bulletin does not apply. Further diagnosis is required. PARTS REQUIRED: REPAIR PROCEDURE: 1. With the Door Panel already removed and "E" clip and cable disconnected, remove the 2 bolts holding the drive motor to the drive unit. 2. Replace sliding door motor. 3. Reinstall cable and "E clip. 4. Install door panel. Refer to the detailed procedures available in DealerConnect > TechConnect under Service Info> 23 Body > Doors - Sliding > Panel, Door Trim > Removal/Install. 5. Preform Power Door Learn Cycle. 6. Test and return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Sliding Door Motor: > 23-007-10 > Jun > 10 > Body - Hard To Manually Open/Close Side Sliding Doors > Page 9054 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Motor > Component Information > Locations > Component Locations Power Sliding Door Motor: Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Motor > Component Information > Locations > Component Locations > Page 9057 Right Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Motor > Component Information > Locations > Page 9058 Power Sliding Door Motor: Diagrams Left Sliding Door Motor (Power Sliding Door) Right Sliding Door Motor (Power Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Motor > Component Information > Locations > Page 9059 Power Sliding Door Motor: Description and Operation Power Sliding Door Components The door motor is located in the center of the power sliding door and is comprised of three parts. The three parts of the door motor assembly are the motor, gear reduction and clutch assembly. The door motor assembly provides the power and torque to move the sliding door from the open/closed position to full closed/open position, after the power latching mechanism has released. The door motor is replaced as a complete assembly, which includes the DC motor, gear reduction and clutch assemblies. With the push of a power sliding door command switch, the power sliding door control module will signal the latch assembly to release the door from its primary locked position. The door motor will then take over to provide the power to open the door to its full open or closed position. The gear reduction portion of the motor assembly reduces the speed of the motor from 5800 to 260 rpm and also increases the torque to the lower drive unit. The clutch portion of the motor assembly engages the motor to drive the door under power and disengages it so the door can be moved easily under manual operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Motor > Component Information > Locations > Page 9060 Power Sliding Door Motor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel from the appropriate door. 3. Remove the water shield as necessary to gain access to motor assembly. Flex Drive Retaining Clip 4. Remove retaining clip holding flex drive assembly to the motor. Pull flex drive cable straight out of the motor assembly. 5. Disconnect door motor electrical connector. 6. Using a trim stick (special tool #C-4755) or equivalent, gently pry out push-pin fasteners retaining the door motor. 7. Remove the door motor assembly from the vehicle. INSTALLATION 1. Position the door motor assembly on the door inner panel. 2. Install the push-pin fasteners retaining the motor assembly to the power sliding door. NOTE: Push in on the push-pins at the clutch housing (plastic side) until you hear one click. Push in on the push-pin fasteners at the motor mount (sheet metal side) until you hear two clicks. This assures proper installation/attachment of the motor to the sliding door. 3. Install the flex shaft by lining up the square shaped drive shaft with the corresponding hole in the door motor drive unit and push straight in. 4. Install the E-clip to secure flex-shaft. 5. Install the weather shield as necessary. 6. Install the door trim panel on the sliding door. 7. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Release Actuator > Component Information > Service and Repair Power Sliding Door Release Actuator: Service and Repair INSIDE HANDLE ACTUATOR REMOVAL 1. Remove latch/lock assembly. Fig. 6 2. Remove lock actuator three attaching screws (Fig. 6). 3. Remove lock actuator. INSTALLATION 1. Place lock actuator into position on latch/lock assembly. 2. Install attaching screws (Fig. 6). 3. Install latch/lock assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Switch > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Switch > Component Information > Locations > Page 9067 Power Sliding Door Switch: Diagrams Left B.Pillar Switch (Power Sliding Door) Left Full Open Switch (Power Sliding Door) Right B.Pillar Switch (power Sliding Door) Right Full Open Switch (Power Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Switch > Component Information > Locations > Page 9068 Right Sliding Door Latch Sensing Switch (Power Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Switch > Component Information > Description and Operation > Full Open Switch Power Sliding Door Switch: Description and Operation Full Open Switch Full Open Switch Position And Orientation The full open switch is located in the hold open latch under the sliding door lower hinge. When the power sliding door control module receives a ground signal input from the full open switch, and as long as the cinching latch actuator is not in power mode or the handle switch is open, the signal indicates that the door is at the full open position. The full open switch is incorporated into the hold open latch. If the full open switch is inoperative, the entire hold open latch assembly must be replaced. The full open switch is triggered by a pawl lever in the hold open latch. When the full open switch is closed (circuit to ground) the ratchet has engaged on the hold open striker and the pawl lever has engaged on the ratchet, locking the latch from opening and holding the door in the full open position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Switch > Component Information > Description and Operation > Full Open Switch > Page 9071 Power Sliding Door Switch: Description and Operation B-Pillar Switch The B-pillar switches are located on the interior of the vehicle, on the B-pillar trim panels. These switches serve as an open and close command switch for the appropriate power sliding door. When the B-pillar switch is depressed a signal is sent to the Body Control Module (BCM), this signal is then sent to the power sliding door control module, telling it to start a power open or close cycle. The child lockout feature must be disabled and the sliding door must be unlocked in order for the B-pillar switch to function. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Power Sliding Door Switch > Component Information > Description and Operation > Page 9072 Power Sliding Door Switch: Service and Repair B-PILLAR SWITCH REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick (special tool # C-4755) or equivalent, gently pry the leading upper edge of the B-pillar switch away from the B-pillar trim. 3. Once the upper edge is free from B-pillar trim, rock the switch out of the switch opening. 4. Disconnect the B-pillar switch electrical connector. First, slide the connector lock away from the switch then, depress connector retaining tab while pulling straight apart. 5. Remove the B-pillar switch from the vehicle. INSTALLATION 1. Connect the B-pillar switch electrical connector. Slide connector lock toward the switch to lock in place. 2. Hook the lower edge of the B-pillar switch on the B-pillar trim and then push the switch firmly into position. 3. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Service and Repair > Inside Handle Cable Sliding Door Handle: Service and Repair Inside Handle Cable INSIDE HANDLE CABLE REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the appropriate side door trim panel from the vehicle. 3. Peel watershield away from adhesive around perimeter of inner door panel. 4. Remove the inside handle assembly from the side door. 5. Disconnect the inside handle cable from the handle assembly. Gently pry cable sleeve retainer out of the handle bracket and then unhook swedged cable end from the handle link. 6. Open the side door and remove the latch assembly. Refer to Sliding Door. CAUTION: Make note of cable routing and foam insulator placement. This will prove helpful when reinstalling replacement cable. Be certain replacement cable is routed and retained correctly. 7. Trace the inside handle cable along its routing path and disconnect from its retaining clips. 8. Disconnect the inside handle cable from the latch assembly. Gently pry cable sleeve retainer out of the latch mounting bracket and then unhook swedged cable end from the latch link. 9. Remove the inside handle cable from the side door. INSTALLATION 1. Match the replacement cable up against the old cable to verify the correct part. 2. Position the inside handle cable on the side door. 3. Connect the inside handle cable on the handle assembly. Hook the swedged cable end on the handle link and gently push the cable sleeve retainer in the handle bracket. 4. Install the inside handle assembly on the side door. NOTE: The inside handle cable is marked with blue tape and must be attached to the latch at the center (just above the lower cable). This position is marked with a "B" on the latch. 5. Connect the inside handle cable on the latch assembly. Hook the swedged cable end on the latch link and gently push the cable sleeve retainer in the latch bracket. 6. Trace the inside handle cable along its routing path and install on its retaining clips and position foam insulators. Use previously made schematic as a guide or remove the opposite side door trim panel and use that door as a guide. CAUTION: Be certain replacement cable is routed and retained correctly and foam insulators are properly positioned. 7. Install the latch assembly. Refer to Sliding Door. 8. Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages. 9. Install the appropriate side door trim panel on the vehicle. 10. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Service and Repair > Inside Handle Cable > Page 9077 Sliding Door Handle: Service and Repair Inside Latch Handle INSIDE LATCH HANDLE REMOVAL 1. Remove sliding door trim panel. Fig. 21 2. Remove screws attaching bottom of inside latch handle to sliding door (Fig. 21). 3. Remove two screw attaching top of inside latch handle to sliding door. 4. Remove latch handle from sliding door. 5. Disengage cable end from clip on release handle mechanism. 6. Disengage cable end from release handle mechanism. 7. Remove push pin fastener attaching cable end to release handle. Fig. 22 8. Disengage cable casing end from release handle (Fig. 22). 9. Disengage cable end from latch handle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Service and Repair > Inside Handle Cable > Page 9078 10. Remove handle from vehicle. INSTALLATION 1. Place inside latch handle in position on vehicle. 2. Engage cable end into latch handle. 3. Engage cable casing end into release handle. 4. Install push pin fastener to hold cable into release handle. 5. Engage cable end into release handle mechanism. 6. Engage clip to hold cable end into release handle mechanism. 7. Place latch handle in position on sliding door. 8. Install screw to hold top of inside release handle to sliding door. 9. Install screws to hold bottom of inside latch handle to sliding door. 10. Verify sliding door operation. Adjust as necessary. 11. Install sliding door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Service and Repair > Inside Handle Cable > Page 9079 Sliding Door Handle: Service and Repair Outside Handle OUTSIDE HANDLE REMOVAL 1. Remove sliding door trim panel. 2. Remove sliding door stop bumper. 3. Peel watershield away from adhesive around perimeter of inner door panel as necessary to access outside release handle fasteners. 4. Disengage clip attaching outside door handle linkage to door cable. 5. Remove linkage from outside door handle. Fig. 24 6. Remove three nuts attaching outside door handle to outer door panel (Fig. 24). 7. Remove outside door handle from vehicle. INSTALLATION 1. Position outside door handle on vehicle. 2. Install nuts attaching outside door handle to outer door panel. 3. Engage clip attaching linkage to outside door handle. 4. Engage rigging cam to latch/lock control mechanism. 5. Move clip on latch/lock control to bottom of slot and engage linkage to latch/lock control. 6. Verify sliding door operation. Adjust as necessary. 7. Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages. 8. Install sliding door stop bumper. 9. Install sliding door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle > Component Information > Service and Repair > Inside Handle Cable > Page 9080 Sliding Door Handle: Service and Repair Outside Handle Cable OUTSIDE HANDLE CABLE REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove stop bumper. 3. Remove the appropriate side door trim panel. 4. Peel watershield away from adhesive around perimeter of inner door panel. CAUTION: Make note of cable routing and foam insulator placement. This will prove helpful when reinstalling replacement cable. Be certain replacement cable is routed and retained correctly. 5. Trace the outside handle cable along its routing path and disconnect from its retaining clips. 6. Disconnect the outside handle cable from the latch assembly. Gently pry cable sleeve retainer out of the latch mounting bracket and then unhook swedged cable end from the latch link. 7. Disconnect the outside handle cable from the handle assembly. Gently pry cable sleeve retainer out of the handle bracket and then unhook swedged cable end from the handle link. 8. Remove the outside handle cable from the side door. INSTALLATION 1. Match the replacement cable up against the old cable to verify the correct part. 2. Position the outside handle cable on the side door. 3. Connect the outside handle cable on the handle assembly. Hook the swedged cable end on the handle link and gently push the cable sleeve retainer in the handle bracket. NOTE: The outside handle cable is marked with red tape. It must be attached to the latch at the lowest point. This is marked with a "R" on the latch. 4. Connect the outside handle cable on the latch assembly. Hook the swedged cable end on the latch link and gently push the cable sleeve retainer in the latch bracket. 5. Trace the outside handle cable along its routing path and install on its retaining clips and position foam insulators. Use previously made schematic as a guide or remove the opposite side door trim panel and use that door as a guide. CAUTION: Be certain replacement cable is routed and retained correctly and foam insulators are properly positioned. 6. Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages. 7. Install the appropriate side door trim panel on the vehicle. 8. Install stop bumper. 9. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Interior Trim Panel > Component Information > Service and Repair > Sliding Door Stop Bumper Bezel Sliding Door Interior Trim Panel: Service and Repair Sliding Door Stop Bumper Bezel SLIDING DOOR STOP BUMPER BEZEL REMOVAL 1. Using a trim stick (C-4755), disengage clips attaching door stop bumper bezel to the door trim panel. Fig. 1 2. Remove bezel from vehicle (Fig. 1). INSTALLATION 1. Place door stop bumper bezel into position (Fig. 1) 2. Engage clips attaching door stop bumper bezel to the door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Interior Trim Panel > Component Information > Service and Repair > Sliding Door Stop Bumper Bezel > Page 9085 Sliding Door Interior Trim Panel: Service and Repair Trim Panel TRIM PANEL REMOVAL 1. Remove sliding door upper frame molding. 2. If removing the left sliding door trim panel, remove screw from inside ash receiver bezel. 3. Remove screw from pull cup. Fig. 20 4. Disengage push-in fasteners holding trim to door panel around perimeter and upper edge of door (Fig. 20). 5. Remove sliding door trim panel from vehicle. INSTALLATION 1. Place sliding door trim panel in position on vehicle. 2. Align locating pins on backside of trim panel to mating holes in the inner door panel. 3. Engage push-in fasteners to hold trim to door panel around perimeter and upper edge of door (Fig. 20). 4. Install pull cup screw. 5. If necessary, install screw from inside ash receiver bezel on left sliding door trim panel. 6. Install sliding door upper frame molding. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Locations Sliding Door Latch: Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Locations > Page 9089 Left Sliding Door Latch Sensing Switch (Power Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Locations > Page 9090 Sliding Door Latch: Service and Repair LATCH / LOCK ASSEMBLY REMOVAL 1. Remove sliding door trim panel. 2. Remove sliding door stop bumper. 3. Peel watershield away from adhesive around perimeter of inner door panel. Fig. 4 4. Disengage external cable from latch/lock assembly (Fig. 4). 5. Remove foam block. 6. Remove inside door handle assembly. 7. Disengage inside cable from latch/lock assembly. 8. Disengage link from bellcrank. 9. Disengage hold open latch cable from lower hinge. Fig. 5 10. Remove bolts attaching latch/lock control to sliding door (Fig. 5). 11. If equipped, lower latch and disconnect wire connector from power door lock motor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch > System Information > Locations > Page 9091 12. Remove latch/lock from door. INSTALLATION 1. Position latch/lock locking lever in unlocked position. 2. If equipped, engage wire connector into power door lock motor (Fig. 4). 3. Place latch/lock in position on door (Fig. 5). CAUTION: REPLACE BOLTS IF INSTALLING NEW LATCH. 4. Insert bolt into slots in sliding door inner panel. 5. Tighten bolts attaching latch/lock assembly to sliding door. 6. Engage inside cable into latch/lock assembly. 7. Install inside door handle assembly. 8. Install foam block. 9. Engage external cable to latch/lock assembly. 10. Engage link rod to bellcrank. 11. Engage hold open latch cable from lower hinge. 12. Engage clip to hold bellcrank link to latch/lock control. 13. Verify sliding door operation. 14. Install latch/lock cover. 15. Insure that enough adhesive remains to securely retain the watershield. Replace as necessary. 16. Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages. 17. Install sliding door stop bumper. 18. Install sliding door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Latch Lockout > System Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Lock Knob > Component Information > Service and Repair Sliding Door Lock Knob: Service and Repair BELLCRANK REMOVAL 1. Remove stop bumper. 2. Remove sliding door trim panel. 3. Peel watershield away from adhesive around perimeter of inner door panel as necessary to gain access to latch bellcrank. Fig. 23 4. Disengage lock link (Fig. 23). 5. Disengage link and sleeve 6. Remove bellcrank by rotating bellcrank to release it from door. 7. Remove bellcrank from vehicle. INSTALLATION 1. Position bellcrank on vehicle. 2. Rotate bellcrank into position. 3. Place lock link into position and engage clip (Fig. 23). 4. Place link and sleeve into position and engage clip. 5. Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages. 6. Install sliding door trim panel. 7. Install stop bumper. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Hold-Open Latch > Component Information > Description and Operation Sliding Door Hold-Open Latch: Description and Operation Removing/Installing Power Latch In Sliding Door One power latch is used for each power sliding door. The latch is located on the trailing edge of the sliding door assembly. This power latch assembly is comprised of many different components which have the ability to perform the power cinch, release, lock, unlock and safety related operations. These components are the door latch, lock/unlock actuator, cinch/release actuator and child lockout, pawl, ratchet and handle switches. The pawl and ratchet switches are used to indicate the primary and secondary latched positions. The cinch latch also provides a connection point for the interior handle, exterior handle and hold open latch cables. If any of the components of the latch assembly are inoperative the complete power latch assembly must be replaced. The power latch performs the same operation as a full manual door latch as well as power cinch, release, lock and unlock operations. The power latch mounted actuator cinches the door closed and latches it in its primary latched position. During a power close cycle, the power cinch actuator will not operate until the power sliding door has reached its secondary latch position (determined by pawl and ratchet switches). During a power open cycle, the power release actuator will stop once the sliding door has moved from the primary latch position. The power latch uses inputs from the lock/unlock actuator, power sliding door control module and child lockout, pawl, ratchet and handle switches to provide safe power cinch and release operations. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Hold-Open Latch > Component Information > Service and Repair > Procedures Sliding Door Hold-Open Latch: Procedures REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the appropriate side door trim panel. 3. Remove the weather shield if necessary. Removing Latch Retaining Bolts 4. Open the side door all the way and remove the door latch retaining bolts. Power Latch Position And Orientation 5. Partially close the door and pull the latch assembly out of the side door inner panel. 6. Disconnect all electrical connectors leading to the latch assembly. 7. Disconnect the inside and outside handle cables from the latch assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Hold-Open Latch > Component Information > Service and Repair > Procedures > Page 9103 8. Disconnect the hold open latch cable from the latch assembly. 9. Disconnect lock actuator link rod from the latch assembly. 10. Remove the latch assembly from the vehicle. INSTALLATION Power Latch Position And Orientation 1. Position the latch assembly in the vehicle. Be certain all latch mounted components are installed on the replacement latch assembly. If not, transfer components from the old latch to the new latch assembly. 2. Connect the lock actuator link rod on the latch assembly. 3. Connect the hold open latch cable on the latch assembly. 4. Connect the inside and outside handle cables on the latch assembly. 5. Connect all electrical connectors leading to the latch assembly. Removing Latch Retaining Bolts Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Hold-Open Latch > Component Information > Service and Repair > Procedures > Page 9104 6. With assistance from another person, position the side door and install the door latch retaining bolts. Torque to 10 - 12 Nm (100 in. lbs.). 7. Install the weathershield if necessary. 8. Install the appropriate side door trim panel. 9. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Hold-Open Latch > Component Information > Service and Repair > Procedures > Page 9105 Sliding Door Hold-Open Latch: Removal and Replacement Hold Open Latch HOLD OPEN LATCH REMOVAL 1. Open sliding door. 2. Remove sliding door sill plate. Refer to Trim Panel. Fig. 2 3. Remove nuts attaching hold open latch to lower roller arm (Fig. 2). 4. Remove hold open latch from lower arm. 5. Disconnect cable from hold open latch. 6. Remove hold open latch from vehicle. INSTALLATION 1. Place hold open latch in position on vehicle. 2. Connect cable to hold open latch. 3. Place hold open latch in position on lower arm. 4. Install nuts attaching the hold open latch to lower roller arm. Tighten nuts to 5 N.m (45 in.lbs.) torque. 5. Install sliding door sill plate. 6. Verify sliding door operation. Hold Open Latch Cable HOLD OPEN LATCH CABLE REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the appropriate side door trim panel from the vehicle. 3. Peel watershield away from adhesive around perimeter of inner door panel. 4. Open the side door and remove the latch assembly. CAUTION: Make note of cable routing and foam insulator placement. This will prove helpful when reinstalling replacement cable. Be certain replacement cable is routed and retained correctly. 5. Trace the hold open latch cable along its routing path and disconnect from its retaining clips. 6. Disconnect the hold open latch cable from the latch assembly. Gently pry cable sleeve retainer out of the latch mounting bracket and then unhook swedged cable end from the latch link. 7. Remove the hold open latch from the side door. 8. Disconnect the hold open latch cable from the hold open latch. Gently pry cable sleeve retainer out of the handle bracket and then unhook swedged cable end from the latch link. 9. Remove the hold open latch cable from the side door. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Hold-Open Latch > Component Information > Service and Repair > Procedures > Page 9106 INSTALLATION 1. Match the replacement cable up against the old cable to verify the correct part. 2. Position the hold open latch cable on the side door. NOTE: The hold open latch cable is marked with white tape. It must be attached to the upper most cable attachment at the latch. This position is marked with a "W" on the latch. 3. Connect the hold open latch cable on the hold open latch assembly. Hook the swedged cable end on the latch link and gently push the cable sleeve retainer in the latch bracket. 4. Install the hold open latch on the side door. 5. Connect the hold open latch cable on the latch assembly. Hook the swedged cable end on the latch link and gently push the cable sleeve retainer in the latch bracket. 6. Trace the outside handle cable along its routing path and install on its retaining clips and position foam insulators. Use previously made schematic as a guide or remove the opposite side door trim panel and use that door as a guide. CAUTION: Be certain replacement cable is routed and retained correctly and foam insulators are properly positioned. 7. Install the latch assembly. 8. Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages. 9. Install the appropriate side door trim panel on the vehicle. 10. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Weatherstrip > Component Information > Service and Repair Sliding Door Weatherstrip: Service and Repair SLIDING DOOR WEATHERSTRIP REMOVAL 1. Open sliding door. 2. Remove door opening sill plate. 3. Loosen B-pillar trim covers. 4. Loosen quarter panel trim panels. 5. From splice at the bottom center of door opening, pull weatherstrip from pinch flange around door opening. INSTALLATION 1. Place splice at the bottom center of door opening, pushing weatherstrip onto pinch flange around door opening. 2. Tighten quarter panel trim panels. 3. Tighten B-pillar trim covers. 4. Install door opening sill plate. 5. Close sliding and check alignment. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Window Glass > System Information > Service and Repair Sliding Door Window Glass: Service and Repair SLIDING DOOR GLASS REMOVAL The temperature of the vehicle should be at least 21 degrees C (70 degrees F) before removing the stationary quarter / sliding door glass. Butyl sealer becomes more pliable at high temperatures. 1. Remove interior trim as necessary to gain access attaching locations on back of glass. 2. Remove nuts holding stationary glass to fence. Fig. 4 3. Using razor knife, cut butyl sealer holding glass to fence from between the mounting studs (Fig. 4). 4. Push glass from opening. INSTALLATION The temperature of the vehicle should be at least 21 degrees C (70 degrees F) before removing the stationary quarter / sliding door glass. Butyl sealer becomes more pliable at high temperatures. The stationary glass fence should be cleaned of all old butyl sealer. 1. Apply a 6 mm (0.25 in.) butyl tape around perimeter of glass assembly encapsulation track. Ensure that the butyl tape is wrapped around the mounting studs. 2. Place the glass into the opening and insert mounting studs through holes in fence. 3. Install nuts to hold stationary glass to fence. CAUTION: Tighten nuts to 3.4 N.m (30 in.lbs.) torque in the sequence indicated. Do not over torque, or glass breakage may result (Fig. 4). 4. Water test before installing interior trim. 5. Install interior trim. 6. Verify alignment and flushness. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Upper Sliding Door Roller > Component Information > Service and Repair Upper Sliding Door Roller: Service and Repair UPPER HINGE REMOVAL 1. Open sliding door, do not latch open. Fig. 25 2. Remove screw attaching upper stop bracket to upper roller bracket (Fig. 25). 3. Remove stop bracket from vehicle. 4. Place a padded block between the open sliding door and the roof rail. 5. Mark outline of upper hinge bracket on sliding door. Fig. 26 6. Remove bolts attaching upper roller to sliding door (Fig. 26). 7. Remove upper hinge from door. 8. Slide roller out of rear end of roof upper channel. 9. Remove upper hinge from vehicle. INSTALLATION 1. Place upper hinge in position on vehicle (Fig. 26). 2. Slide roller into rear end of roof upper channel. 3. Place upper hinge in position on door. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Upper Sliding Door Roller > Component Information > Service and Repair > Page 9116 4. Align outline marks on sliding door to upper roller bracket 5. Install bolts attaching upper hinge to sliding door. 6. Remove padded block from between sliding door and roof rail. 7. Place stop bracket in position on vehicle. 8. Install screw attaching upper stop bracket to upper roller bracket (Fig. 25). 9. Verify sliding door alignment and operation. Adjust as necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Striker > Component Information > Service and Repair > Hold Open Latch Striker Sliding Door Striker: Service and Repair Hold Open Latch Striker HOLD OPEN LATCH STRIKER REMOVAL 1. Open sliding door, do not latch open. 2. Remove sliding door sill plate. Refer to Trim Panel. Fig. 3 3. Remove two bolts attaching sliding door hold open latch striker to door sill (Fig. 3). 4. Remove hold open latch striker from vehicle. INSTALLATION 1. Place hold open latch striker in position on vehicle. 2. Install two bolts attaching sliding door hold open latch striker to door sill. 3. Install sliding door sill plate. 4. Verify sliding door operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Striker > Component Information > Service and Repair > Hold Open Latch Striker > Page 9121 Sliding Door Striker: Service and Repair Center Striker CENTER STRIKER REMOVAL 1. Remove sliding door trim panel. 2. Remove bolts attaching stop bumper. Remove stop bumper from door. Fig. 7 3. Remove screws attaching center striker assembly to door end frame (Fig. 7). 4. Remove center striker assembly from door through access hole. INSTALLATION 1. Place center striker in position on door through access hole (Fig. 7). 2. Install screws to attach center striker to door end frame. 3. Install bolts attaching stop bumper. 4. Install sliding door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Striker > Component Information > Service and Repair > Hold Open Latch Striker > Page 9122 Sliding Door Striker: Service and Repair Rear Latch Striker REAR LATCH STRIKER REMOVAL 1. Open sliding door. 2. Mark outline of striker on C-pillar door jamb face to aid installation. Fig. 9 3. Remove screws attaching striker to C-pillar (Fig. 9). 4. Remove striker from vehicle. INSTALLATION 1. Place striker in position on vehicle. 2. Align striker to outline marks on C-pillar. 3. Install screws attaching striker to C-pillar. Tighten screws to 28 N.m (21 ft.lbs.) torque. 4. Verify sliding door alignment and operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Fuel Fill Door Fuel Door: Service and Repair Fuel Fill Door FUEL FILL DOOR REMOVAL 1. Remove left quarter trim panel. 2. Remove water shield patch covering access hole in C-pillar. Fig. 12 3. Disengage latch release link from clip on fuel fill blocker latch arm (Fig. 12). 4. Open fuel fill door. 5. Remove screws holding fuel fill neck to fuel filler housing. 6. Position fuel fill neck out of the way. Fig. 9 7. Reaching inside fuel filler housing, release clips holding housing to quarter panel (Fig. 9). 8. Remove fuel fill door from vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Fuel Fill Door > Page 9127 Fig. 13 9. Disengage clip holding link to fuel fill door (Fig. 13). 10. Remove link from fuel fill door. INSTALLATION 1. Install spring to housing and door 2. Snap door into housing. 3. Insert lockout link into clip on fuel fill door. 4. Engage clip to hold link to fuel fill door. 5. Insert lockout link through grommet in panel between inner and outer quarter panel. 6. Close fuel fill door. 7. Install fuel filler housing to outer quarter panel. 8. Verify that all clips on fuel filler housing are fully engaged to outer quarter panel. 9. Place fuel fill neck in position. 10. Install screws to hold fuel fill neck to fuel filler housing. 11. Engage latch release link into clip on fuel fill blocker latch arm. 12. Verify fuel fill blocker latch operation. 13. Install water shield patch to cover access hole in C-pillar. 14. Install left quarter trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Fuel Fill Door > Page 9128 Fuel Door: Service and Repair Fuel Fill Door Blocker Latch FUEL FILL DOOR BLOCKER LATCH REMOVAL 1. Remove left quarter trim panel. 2. Remove water shield patch covering access hole in C-pillar. Fig. 12 3. Disengage latch release link from clip on fuel fill blocker latch arm (Fig. 12). Fig. 10 4. Remove screws holding fuel fill blocker latch to C-pillar (Fig. 10). 5. Remove fuel fill blocker latch from vehicle. INSTALLATION 1. Position fuel fill blocker latch on vehicle. 2. Install screws to hold fuel fill blocker latch to C-pillar. 3. Engage latch release link into clip on fuel fill blocker latch arm with fuel door in the closed position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Fuel Fill Door > Page 9129 4. Install water shield patch to cover access hole in C-pillar. 5. Verify fuel fill blocker latch operation. 6. Install left quarter trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Fuel Fill Door > Page 9130 Fuel Door: Service and Repair Fuel Fill Door Blocker Latch Striker FUEL FILL DOOR BLOCKER LATCH STRIKER REMOVAL 1. Remove sliding door trim panel. 2. Remove sound shield as necessary to access striker Fig. 11 3. Remove screw attaching fuel fill door blocker latch striker to sliding door rear end frame. (Fig. 11) 4. Remove fuel fill door blocker latch striker from vehicle. INSTALLATION 1. Position fuel fill door blocker latch striker on vehicle. 2. Install screws attaching fuel fill door blocker latch striker to sliding door rear end frame. 3. Install sliding door sound shield. 4. Install sliding door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Fuel Fill Door > Page 9131 Fuel Door: Service and Repair Fuel Fill Door Blocker Lockout Link FUEL FILL DOOR BLOCKER LOCKOUT LINK REMOVAL 1. Remove left quarter trim panel. 2. Remove water shield patch covering access hole in C-pillar. Fig. 12 3. Disengage fuel filler lockout link from clip on fuel fill blocker latch arm (Fig. 12). 4. Open fuel fill door. 5. Remove screws holding fuel filler housing to fuel filler tube neck. 6. Reaching inside fuel filler housing, release clips holding housing to outer quarter panel. 7. Remove fuel filler housing and lockout link from vehicle. Fig. 13 8. Disengage clip holding link to fuel fill door (Fig. 13). 9. Remove link from fuel fill door. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Fuel Fill Door > Page 9132 INSTALLATION 1. Insert link into clip on fuel fill door. 2. Engage clip to hold link to fuel fill door. 3. Insert lockout link through grommet in panel between inner and outer quarter panel. 4. Close fuel fill door. 5. Install fuel filler housing to outer quarter panel. 6. Verify that all clips on fuel filler housing are fully engaged to outer quarter panel. 7. Install screws attaching fuel fill housing to fuel filler tube neck. 8. Engage fuel filler lockout link into clip on fuel fill blocker latch arm. 9. Install water shield patch covering access hole in C-pillar. 10. Install left quarter trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair Hood Hinge: Service and Repair HINGE REMOVAL 1. Remove Front Wiper Unit. 2. Raise hood. 3. Mark all bolt and hinge attachment locations with a grease pencil or other suitable device to provide reference marks for installation. 4. Remove pivot bolt from the body half of hood hinge and use suitable device to support the hood. Fig. 1 5. Remove bolts attaching body half of hood hinge to front fender flange and remove hinge from vehicle (Fig. 1). INSTALLATION 1. If necessary, paint new hinge before installation. 2. Place body half of hood hinge in position on vehicle. 3. Install bolts attaching hood hinge to front fender flange. Tighten bolts to 8 N.m (70 in.lbs.) torque. 4. Install pivot bolt to the body half of hood hinge. Tighten bolts to 28 N.m (21 ft.lbs.) torque. 5. Install Front Wiper Unit. 6. Align all marks and secure bolts. The hood should be aligned to 4 mm (0.160 in.) gap to the front fenders and flush across the top surfaces along fenders. Shims can be added or removed under hood hinge to achieve proper hood height. Tighten bolts to 13.5 N.m (10 ft.lbs.) torque. Close hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair Hood Latch: Service and Repair LATCH REMOVAL 1. Release hood latch and open hood. Fig. 3 2. Remove bolts attaching hood latch to radiator closure panel crossmember (Fig. 3). 3. Remove hood latch from crossmember. Fig. 4 4. Disconnect hood release cable from hood latch (Fig. 4). 5. Remove hood latch from vehicle. INSTALLATION 1. Connect hood release cable from hood latch. 2. Position hood latch on crossmember. 3. Align hood latch by placing latch over net pierced tabs. If alignment is required, flatten or grind tabs. 4. Verify hood operation and alignment. Adjust as necessary. 5. Tighten attaching bolts to 13.5 N.m (10 ft.lbs.) torque. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair Hood Latch Release Cable: Service and Repair LATCH RELEASE CABLE REMOVAL 1. Remove hood latch. 2. Disengage cable end from hood latch locking mechanism. 3. Slide cable case end sideways in keyhole slot of hood latch while pinching barb on cable case closed. Fig. 4 4. Remove cable from latch (Fig. 4). 5. Remove hood release handle from instrument panel. 6. Disengage rubber grommet cable insulator from hole in dash panel. 7. Attach a suitable length of mechanic's wire to latch end of cable to assist cable installation. Fig. 5 8. Route cable back from latch through engine compartment toward dash panel near power brake booster (Fig. 5). 9. Remove attaching clips from cable case. 10. From inside vehicle, pull cable through dash panel until mechanic's wire is exposed. 11. Disconnect cable from mechanic's wire. 12. Remove hood release cable from vehicle. INSTALLATION 1. Place hood release cable in position under instrument panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 9143 2. Attach latch end of hood release cable to mechanic's wire protruding through dash panel. 3. Route cable forward through engine compartment toward latch by pulling on mechanic's wire (Fig. 5). 4. Disconnect mechanic's wire from cable. 5. Engage rubber grommet cable insulator into hole in dash panel. 6. Install hood release handle into instrument panel. 7. Place cable in position on latch. 8. Slide cable case end sideways into keyhole slot of hood latch. 9. Engage cable end into hood latch locking mechanism. 10. Install hood latch. 11. Install attaching clips to cable case and install clips into original holes in strut tower, fender, headlamp area, and radiator closure panel crossmember. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Striker > Component Information > Service and Repair Hood Striker: Service and Repair LATCH STRIKER REMOVAL 1. Release hood latch and open hood. 2. Remove bolts attaching striker to inside of hood. 3. Remove hood latch striker from vehicle. INSTALLATION 1. Position hood latch striker on vehicle, aligning with paint breaks. 2. Install bolts attaching hood latch striker to hood. 3. Align hood latch striker to engage smoothly into hood latch. 4. Verify hood operation and alignment. Adjust as necessary. 5. Tighten attaching bolts to 13.5 N.m (10 ft.lbs.) torque. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component Locations Hood Sensor/Switch (For Alarm): Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component Locations > Page 9152 Left Side Engine Compartment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 9153 Hood Sensor/Switch (For Alarm): Service and Repair HOOD AJAR SWITCH-EXPORT REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a small flat blade screwdriver, pry trigger switch from the bracket on the left fender well. 3. Disconnect the hood ajar switch from the wire connector and remove from vehicle. INSTALLATION 1. Connect the hood ajar switch to the wire connector. 2. Press the hood ajar switch into position on the bracket located on the left inner fender well. 3. Reconnect the battery negative cable. 4. Close the hood and check for proper operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair LIFTGATE GLASS REMOVAL Refer to the Service Precautions for description of tools and adhesive systems that are recommended for use in this procedure. REAR WINDOW REMOVAL - EXTERIOR METHOD 1. Remove rear window wiper arm. 2. Remove interior trim covers. 3. Disconnect wires for electrically heated window, if equipped. Fig. 1 4. Using a sharp cold knife, cut urethane adhesive attaching the rear window to the liftgate. A power cutting device can be used if available (Fig. 1). 5. Remove rear window from vehicle. INSTALLATION Refer to the Service Precautions for description of tools and adhesive systems that are recommended for use in this procedure. CAUTION: Open the left front door glass before installing rear window to avoid pressurizing the passenger compartment. If a door is slammed before urethane bonding is cured, water leaks can result. Allow the urethane at least 24 hours to cure before returning the vehicle to use. To avoid stressing the replacement rear window,the urethane bonding material on the rear window fence should be smooth and consistent to the shape of the replacement glass. 1. Place replacement glass into rear window opening. 2. Verify the glass lays evenly against the pinch weld fence at the sides, top and bottom of the replacement rear window. If not, the urethane adhesive remaining on the fence must be formed to the shape of the new glass. 3. Using a grease pencil, mark the glass and lift-gate in several locations to aid installation. 4. Remove replacement glass from liftgate opening. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Page 9158 Fig. 2 5. Position the rear window inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed parallel 75 cm (2.5 ft.) apart (Fig. 2). WARNING: DO NOT USE SOLVENT BASED GLASS CLEANER TO CLEAN REAR WINDOW BEFORE APPLYING GLASS PREP AND PRIMER. POOR ADHESION CAN RESULT. 6. Clean inside of rear window with ammonia based glass cleaner and lint-free cloth. 7. Apply Glass Prep adhesion promoter 25 mm (1 in.) wide around perimeter of rear window and wipe with clean/dry lint-free cloth until no streaks are visible. 8. Apply Glass Primer 25 mm (1 in.) wide around perimeter of rear window. Allow at least three minutes drying time. 9. Apply Pinch weld Primer 19 mm (0.75 in.) wide around the rear window fence. Allow at least three minutes drying time. 10. If a low viscosity urethane adhesive is used, install compression spacers on the fence around the rear window opening. 11. Apply a 10 mm (0.4 in.) bead of urethane along center line of rear window fence. CAUTION: Be careful so that spacers do not contaminate urethane bead. 12. Apply 2 glass spacer clips to bottom edge of glass, approximately 150 mm (6.0 inches) inboard from each corner. 13. With the aid of a helper, position the rear window over the rear window opening and align the reference marks. 14. Slowly lower glass to rear window opening fence. Ensure spacers on bottom edge of glass contact sheet metal ledge. Then, push glass inward until flush to liftgate surface. 15. Clean excess urethane from exterior with Mopar(R) Super Kleen, or equivalent. 16. Apply 150 mm (6 in.) lengths of 50 mm (2 in.) masking tape spaced 250 mm (10 in.) apart to hold molding in place until urethane cures. 17. Install rear window wiper arm. 18. Install interior trim. 19. After urethane has cured, remove tape strips, slide out bottom spacer clips, and then water test rear window to verify repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Trunk / Liftgate Control Module: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly Power Trunk / Liftgate Control Module: Customer Interest Body - Power Liftgate Does Not Open/Close Properly NUMBER: 08-045-06 GROUP: Electrical DATE: October 17, 2006 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. WHILE THE FILES ARE CURRENTLY AVAILABLE FROM THE INTERNET FOR ALL MARKETS, FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE DRBIII(R) FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL ALSO BE AVAILABLE ON ITIL/ISIS DVD 4th QUARTER, 2006. SUBJECT: Flash: Power Liftgate May Not Open Or Close The First Time That The Power Liftgate Button Is Depressed OVERVIEW: This bulletin involves selectively erasing and reprogramming the Power Liftgate Module with new software. MODELS: 2002 - 2007 (RS/RG) Town & Country/Caravan/Voyager NOTE: This bulletin applies to vehicles equipped with a Power Liftgate (sales code JRC) built on or before October 13, 2006 (MDH 1013XX). SYMPTOM/CONDITION: The vehicle operator may describe that the Power Liftgate may not open or close the first time that the Power Liftgate button is depressed. If the button is pressed repeatedly, the liftgate will open or close properly. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII® connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE FOR DOMESTIC VEHICLES DOWNLOADING FLASH FILES FROM DealerCONNECT> Tech TOOLS: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Trunk / Liftgate Control Module: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly > Page 9167 NOTE Remove any unnecessary PCMCIA cards prior to starting a DRBIII(R) flash. 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the Power Liftgate Module currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2007 Diagnostics". c. "All (Except Below)". d. "Body Interior". e. "Doors, Gates & Comfort". f. "Power Lift Module". g. "Module Display". h. Record the "Power Liftgate Module part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "Power Liftgate Module part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the '~Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to next step. NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Trunk / Liftgate Control Module: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly > Page 9168 Due to the Power Liftgate Module programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Trunk / Liftgate Control Module: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly Power Trunk / Liftgate Control Module: All Technical Service Bulletins Body - Power Liftgate Does Not Open/Close Properly NUMBER: 08-045-06 GROUP: Electrical DATE: October 17, 2006 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. WHILE THE FILES ARE CURRENTLY AVAILABLE FROM THE INTERNET FOR ALL MARKETS, FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE DRBIII(R) FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL ALSO BE AVAILABLE ON ITIL/ISIS DVD 4th QUARTER, 2006. SUBJECT: Flash: Power Liftgate May Not Open Or Close The First Time That The Power Liftgate Button Is Depressed OVERVIEW: This bulletin involves selectively erasing and reprogramming the Power Liftgate Module with new software. MODELS: 2002 - 2007 (RS/RG) Town & Country/Caravan/Voyager NOTE: This bulletin applies to vehicles equipped with a Power Liftgate (sales code JRC) built on or before October 13, 2006 (MDH 1013XX). SYMPTOM/CONDITION: The vehicle operator may describe that the Power Liftgate may not open or close the first time that the Power Liftgate button is depressed. If the button is pressed repeatedly, the liftgate will open or close properly. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII® connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE FOR DOMESTIC VEHICLES DOWNLOADING FLASH FILES FROM DealerCONNECT> Tech TOOLS: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Trunk / Liftgate Control Module: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly > Page 9174 NOTE Remove any unnecessary PCMCIA cards prior to starting a DRBIII(R) flash. 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the Power Liftgate Module currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2007 Diagnostics". c. "All (Except Below)". d. "Body Interior". e. "Doors, Gates & Comfort". f. "Power Lift Module". g. "Module Display". h. Record the "Power Liftgate Module part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "Power Liftgate Module part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the '~Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to next step. NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Trunk / Liftgate Control Module: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly > Page 9175 Due to the Power Liftgate Module programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 9176 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 9177 Power Trunk / Liftgate Control Module: Description and Operation Power Liftgate Control Module Vehicles equipped with a power liftgate (PLG) utilize a PLG control module. This module is located on the vehicles left side D-pillar just below the motor assembly and contains a microprocessor, which is used to communicate to the vehicles body control module. The PLG control module receives and monitors logic inputs from all the PLG system switches except for the outside handle switch. This module also contains the software technology to detect liftgate obstructions and stop and/or reverse the door accordingly. The power liftgate control module contains the electronic circuitry and software used to control the sequence of events for the power liftgate system. This module communicates on the Programmable Communications Interface (PCI) bus circuit with the vehicles Body Control Module (BCM) to monitor many different inputs and outputs such as door lock status, transmission gear selector position and vehicle speed. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 9178 Power Trunk / Liftgate Control Module: Testing and Inspection Any diagnosis of the Power Liftgate system should begin with the use of the DRB III(R) diagnostic tool. Inspect the related wiring harness connectors for broken, bent, pushed out, or corroded terminals. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 9179 Power Trunk / Liftgate Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left D-pillar trim panel from the vehicle. 3. Disconnect the wire harness connections from the power liftgate motor assembly. Power Liftgate Control Module 4. Remove the screw holding the power liftgate control module to the D-pillar. 5. Remove the power liftgate control module from the vehicle. INSTALLATION 1. Install the Power Liftgate (PLG) control module on the D-pillar and install retaining screw. 2. Connect the wire harness connections to the PLG control module. Be certain to slide connector locks to the locked position. 3. Install the D-pillar trim panel on the vehicle. 4. Connect the battery negative cable. 5. Using an appropriate scan tool, check and erase any PLG control module diagnostic trouble codes. 6. Verify PLG system operation. Cycle the PLG through one complete open and close cycle, this will allow the PLG control module to relearn its cycle with the new components. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Page 9183 Power Liftgate Motor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 9187 Power Trunk / Liftgate Lock Switch: Diagrams Liftgate Ajar Switch (Manual Release) Liftgate Ajar Switch (power Release) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Sensor > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Sensor > Component Information > Locations > Page 9191 Power Trunk / Liftgate Hazard Sensor: Description and Operation Pinch sensors are located on each side of the lift-gate. These sensors look like weather-strips, however they consist of pieces of electrically conductive rubber (tapeswitch), wires, resistor, double sided tape, and a plastic carrier. They are used to indicate an obstruction during a power liftgate close cycle. During a power liftgate close cycle, if either of the two conductive rubber strips (tapeswitch) of the pinch sensor come in contact with an obstacle, the pinch sensor circuit is completed. This tells the power liftgate control module that a obstruction is felt. The control module will stop the liftgate immediately and return it to the full open position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Sensor > Component Information > Locations > Page 9192 Power Trunk / Liftgate Hazard Sensor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove trim panel from liftgate. Pinch Sensor Location 3. Disconnect the pinch sensor wire harness connector. 4. Remove screws holding the pinch sensor to lift-gate. 5. Feed the pinch sensor wire harness out of the liftgate and remove the sensor from the vehicle. INSTALLATION WARNING: USE EXTREME CAUTION WHEN TESTING PINCH SENSOR OPERATION. CAUTION: Ensure liftgate surface is clean and dry prior to pinch sensor installation. Failure to do so will inhibit the adhesive backings ability to adhere to the liftgate and cause improper system operation or premature component failure. 1. Position the pinch sensor to the liftgate. 2. Install the third screw from the top of the sensor first. Do not torque screw at this time. 3. Install the remaining three screws holding the sensor to the liftgate. Torque all screws to 25 in. lbs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Sensor > Component Information > Locations > Page 9193 Pinch Sensor Location 4. Install wire harness grommet in liftgate flange and route, connect the pinch sensor wire harness connector. 5. Remove protective tape from the top of the pinch sensor. Firmly apply pressure to the sensor adhesive to secure it to the liftgate. 6. Install the trim panel on the liftgate. 7. Connect the battery negative cable. 8. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes related to the pinch sensor. 9. Verify power liftgate system and pinch sensor operation. Cycle the power liftgate through one complete open and close cycle, during the final close cycle press the pinch sensor to verify the power liftgate detects an obstruction and returns to the full open position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair Trunk / Liftgate Hinge: Service and Repair HINGE REMOVAL 1. Release liftgate latch and open liftgate. 2. Support liftgate on a suitable lifting device in the full open position. 3. Apply several layers of duct tape on the outside of to roof across the gap to the lift gate to hold the liftgate in position. 4. Remove bolts attaching liftgate hinge to roof header. 5. Disconnect VTSS switch from the body harness. Fig. 1 6. Remove bolts attaching hinge to liftgate (Fig.1). 7. Remove hinge from vehicle. INSTALLATION 1. If necessary, paint replacement hinge before installation. 2. Place hinge in position on vehicle. 3. Align hinge to marks on liftgate. 4. Install bolts attaching hinge to liftgate (Fig. 1). Tighten bolts to 33 N.m (24 ft.lbs.) torque. 5. Align hinge to marks on roof header. 6. Install bolts attaching liftgate hinge to roof header. Tighten outer two bolts to 33 N.m (24 ft.lbs.) torque. The sheet medal screw at center 12 N.m (105 in.lbs.) 7. Remove duct tape from roof and liftgate. 8. Verify liftgate alignment. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair Trunk / Liftgate Handle: Service and Repair EXTERIOR HANDLE REMOVAL 1. Remove liftgate trim panel. 2. Disconnect the exterior handle electrical connectors. 3. Remove the two outer screws and the two inner screws. 4. Remove the exterior handle/license plate light assembly. INSTALLATION 1. Route the exterior handle electrical connector through the door and position handle. 2. Install the two out screws and tighten to 3 N.m (22 in.lbs.). 3. Install the two inner bolts and tighten to 5 N.m (40 in.lbs.). 4. Connect the electrical connector. 5. Install the trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair Trunk / Liftgate Interior Trim Panel: Service and Repair TRIM PANEL REMOVAL Fig. 6 1. Remove the bolt attaching the lift motor link, if equipped (Fig. 6). Fig. 7 2. Remove liftgate upper frame molding (Fig. 7). 3. Remove assist handle screws. 4. Disengage hidden clips holding trim panel to liftgate from around perimeter or liftgate (Fig. 7). 5. Disconnect wire connector from lamps. 6. Remove liftgate trim panel from vehicle. INSTALLATION 1. Place liftgate trim panel in position on vehicle. 2. Engage hidden clips to hold trim panel to liftgate and fasteners around perimeter of liftgate (Fig. 7). 3. Connect wire connector into lamp. 4. Install courtesy lamps into liftgate trim. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Page 9203 5. Install screws to hold assist handle to liftgate. 6. Install upper frame side moldings. 7. Install liftgate upper frame molding. 8. Install the bolt attaching the liftgate motor link and tighten to 28 N.m (21 ft.lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Description and Operation > Latch Trunk / Liftgate Latch: Description and Operation Latch Power Latch Orientation The power cinch/release latch performs the same features as a manual liftgate latch as well as the power cinch and / or release capability. A second type of power latch can also be found on some vehicles, this latch is designed to perform a power release only. The power cinch and release capability is accomplished by an actuator mounted to the leading edge of the latch assembly. The latch is located in the lower center of the power liftgate assembly and contains integral pawl and ratchet switches. The ratchet switch also acts as a liftgate ajar switch. The power latch assembly can be serviced as a complete assembly, latch without actuator or just the actuator. On the power cinch/release latch, the latch mounted actuator provides the torque required to close the power liftgate from the secondary to the primary closed and latched position. On the power cinch/release latch and the power release only latch, the actuator releases the liftgate from the primary closed and latched position to the fully unlatched and movable position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Description and Operation > Latch > Page 9208 Trunk / Liftgate Latch: Description and Operation Latch Actuator Power Latch Orientation The power cinch and/or power release latch is made possible by a latch actuator attached to the leading edge of the power latch assembly. This 12 volt latch actuator contains a small drive gear that meshes with the latch assemblies internal gears to perform the power cinch close / power release operations. During a power close cycle, the power cinch actuator provides the torque required to close the power liftgate from the secondary to the primary closed and latched position. During a power open cycle, the power release actuator releases the liftgate from the primary closed and latched position to the fully unlatched and movable position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Procedures Trunk / Liftgate Latch: Procedures Latch REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the liftgate and remove the liftgate trim panel. Power Latch Orientation 3. Disconnect the power latch electrical connector. 4. Remove the power latch retaining bolts. 5. Disconnect the liftgate lock cylinder link rod from the key cylinder or latch assembly. To disconnect from latch, rotate the plastic retaining clip 90 ° to unsnap clip from linkrod. Then pull link rod straight out of latch arm. 6. Remove the power latch from the vehicle. INSTALLATION 1. Position the power latch in the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Procedures > Page 9211 Power Latch Orientation 2. Connect the liftgate lock cylinder link rod on the cinch latch assembly. Rotate the plastic retaining clip 90 ° to lock retaining clip onto the link rod. 3. Connect the link rod on the lock cylinder. 4. Install three new power latch retaining bolts. Torque to 10 Nm (90 in. lbs.). 5. Connect the power latch electrical connector and secure push pin retainers. 6. Connect the battery negative cable. 7. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes related to the power latch. 8. Verify power liftgate system and power cinch / release latch operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. 9. Verify power liftgate manual operation. Using liftgate key rotate the lock cylinder to verify door operation. Pull door open using exterior liftgate handle / switch. 10. Install the liftgate trim panel. Latch Actuator REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the liftgate and remove the lower liftgate trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Procedures > Page 9212 Power Latch Orientation 3. Disconnect the power latch electrical connector. 4. Remove the three latch retaining bolts. 5. Grab the latch assembly and unhook the key cylinder link rod from the key cylinder. 6. Place the latch assembly on a bench and locate the three wires leading from the actuator portion of the latch assembly. 7. Disengage the main connector retaining push pins from the latch actuator housing. 8. Back the three wires out of the main latch electrical connector. 9. Flip the latch assembly over and remove the latch actuator retaining screw(s). 10. Remove the latch actuator from the latch assembly. INSTALLATION 1. Install the latch actuator onto the latch assembly. 2. Install the three latch actuator retaining screws. 3. Install the three wires in the main latch electrical connector. NOTE: Be certain wires are reinstalled in the correct wire cavities. Failure to do so could result in damage to the latch actuator. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. 4. Secure the main connector retaining push pins on the latch actuator housing. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Procedures > Page 9213 Power Latch Orientation 5. Grab the latch assembly and hook the key cylinder link rod on the key cylinder. 6. Position the latch and install three new latch retaining bolts. Torque to 10 Nm (90 in. lbs.). 7. Connect the power latch electrical connector. 8. Install the lower liftgate trim panel. 9. Connect the battery negative cable. 10. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes related to the power latch. 11. Verify power liftgate system and power cinch / release latch operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. 12. Verify power liftgate manual operation. Using liftgate key rotate the lock cylinder to verify door operation. Pull door open using exterior liftgate handle / switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Procedures > Page 9214 Trunk / Liftgate Latch: Removal and Replacement LATCH REMOVAL 1. Remove liftgate trim panel. 2. Disengage outside key cylinder link from clip on latch. Fig. 2 3. Disconnect wire connector from liftgate latch (Fig. 2). 4. Remove screws attaching latch to liftgate. 5. Remove latch from vehicle. INSTALLATION 1. Engage key cylinder link and place latch in position on vehicle. 2. Install screws attaching latch to liftgate. Tighten to 11 N.m (95 in.lbs.) torque. 3. Connect wire connector to liftgate latch. 4. Verify liftgate fit and operation. Adjust as necessary. 5. Install liftgate trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock > System Information > Locations Trunk / Liftgate Lock: Locations Liftgate And Sliding Door Modules Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock > System Information > Locations > Page 9218 Left Rear Body Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock > System Information > Locations > Page 9219 Liftgate Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock > System Information > Locations > Page 9220 Trunk / Liftgate Lock: Diagrams C315 (Power Liftgate) C315 (Power Liftgate) Left Liftgate Flood Lamp (Export) Liftgate Cinch/Release Motor (Power Liftgate) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock > System Information > Locations > Page 9221 Power Liftgate Module C1 Power Liftgate Module C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair LOCK CYLINDER REMOVAL 1. Remove the liftgate trim panel. 2. Disconnect the electrical connector. 3. Disconnect the latch rod. 4. Rotate plastic lock cylinder nut one quarter turn and remove nut and spring washer. 5. Remove the lock cylinder from the liftgate. INSTALLATION 1. Install lock cylinder into liftgate. 2. Install the plastic lock cylinder lock nut, spring washer and rotate one quarter turn. 3. Connect the electrical connector. 4. Connect the latch rod. 5. Install the trim panel. 6. Verify lock cylinder operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Locations > Component Locations Trunk / Liftgate Motor: Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Locations > Component Locations > Page 9229 Right Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Locations > Page 9230 Trunk / Liftgate Motor: Diagrams Left Cinch Release Motor (Power Sliding Door) Right Cinch/Release Motor (Power Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Description and Operation > Engage Actuator Trunk / Liftgate Motor: Description and Operation Engage Actuator Liftgate Gear Motor Assembly The 12 volt engage actuator provides the engagement and disengagement of the liftgate gear motor to the lift gear by way of an over center link, activated by a lever. The engage actuator is a serviceable component and cannot be repaired, if found to be inoperative it must be replaced. The engage actuators normal position is disengaged. When a power liftgate open or close command is generated from any of the command switches, the power liftgate control module signals the engage actuator to move its lever to the engaged position. This engages the gear motor to the lift gear, so when the motor turns the lift gate moves upward or downwards depending on its current position. During a manual liftgate open or close cycle the engage actuator is disengaged, allowing unrestricted liftgate movement. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Description and Operation > Engage Actuator > Page 9233 Trunk / Liftgate Motor: Description and Operation Liftgate Motor Power Liftgate Components The gear motor assembly consists of a DC motor, hall effect sensor, engage actuator, full open switch, lift gear, aluminum housing, drive gears and wire harness. The gears and motor portion of the assembly provides the power and torque required to open or close the liftgate. The hall effect sensor is used to provide the liftgate control module with a speed reading, which is used to monitor the resistance of liftgate travel. This speed reading also allows the power liftgate control module to detect obstructions and move the liftgate accordingly. The engage actuator is used to toggle between power open/close mode and full manual mode when desired. The full open switch is used to let the power liftgate control module know when the liftgate is approaching the full open position. Serviceable components of the power liftgate gear/ motor assembly are the complete gear/motor assembly, motor and wire harness, lift gear and control rod, engage actuator, full open switch and the transverse bracket. With the push of a power liftgate command switch (liftgate closed), the power liftgate control module will signal the latch assembly to release the liftgate from its primary closed and latched position to the released and movable position. The liftgate motor-mounted engage actuator then engages the liftgate motor assembly, which moves the liftgate into the open position. The liftgate motor provides the torque and power to move the door to its full open or closed position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Description and Operation > Engage Actuator > Page 9234 Trunk / Liftgate Motor: Description and Operation Lift Gear And Link Rod Liftgate Gear/Motor Assembly The lift gear and rod assembly are located in the left rear of the vehicle and are visible without removing the D-pillar trim. The lift gear provides the leverage to move the liftgate from the closed to the open position. The lift gear attaches to a bearing on the gear motor assembly with four bolts. On the outboard side of the lift gear are riveted on teeth, which mesh with the gear motor assembly drive gears during a open or close operation. The rod assembly is a steel shaft, equipped with two spherical rod ends which attaches the lift gear to the lift-gate. The lift gear and rod assembly are serviceable components. One end of the rod assembly is attached to the lift-gate, the other attached to the lift gear. When the lift gear is driven by the gear motor assembly the lift-gate is moved to the open or closed position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Description and Operation > Engage Actuator > Page 9235 Trunk / Liftgate Motor: Description and Operation Transverse Bracket Liftgate Gear/motor Assembly The transverse bracket is used to support and secure the power liftgate gear/motor assembly to the left rear body D-pillar. The transverse bracket is a serviceable power liftgate component. The power liftgate transverse bracket supports the gear motor assembly by supplying an additional attachment point. Located on the leading edge of the gear motor assembly, one end of the transverse bracket attaches to the motor assembly the other to the leading edge of the vehicles D-pillar. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Service and Repair > Engage Actuator Trunk / Liftgate Motor: Service and Repair Engage Actuator REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left rear D-pillar trim from the vehicle. 3. Manually engage the actuator link rod, this must be done to access one of the engage actuator retaining screws. Liftgate Gear Motor Assembly 4. Remove the two engage actuator retaining screws. 5. Disconnect the engage actuator electrical connector and remove the engage actuator from the vehicle. INSTALLATION 1. Position the engage actuator in the vehicle and connect the engage actuator electrical connector. 2. Install the two engage actuator retaining screws. 3. Manually disengage the actuator. 4. Install the left rear D-pillar trim on the vehicle. 5. Connect the battery negative cable. 6. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes. 7. Verify power liftgate system and engage actuator operation. Cycle the power liftgate through one complete open and close cycle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Service and Repair > Engage Actuator > Page 9238 Trunk / Liftgate Motor: Service and Repair Liftgate Motor REMOVAL The power liftgate gear/motor assembly is serviced in two ways: the complete gear/motor assembly, or the motor, aluminum housing, drive gears and wire harness assembly. To perform this service, use the following procedure to remove the gear/motor assembly from the vehicle. Then refer to the other procedures called out to transfer the remaining components (engage actuator, full open switch, transverse bracket and lift gear and rod) to the replacement gear/motor assembly. 1. Disconnect and isolate the battery negative cable. 2. Remove the left rear D-pillar trim panel from the vehicle. Power Liftgate Components 3. Disconnect the wire harness connector from the motor assembly. 4. Remove the two bolts from the motor housing and the one bolt from the transverse mount bracket. 5. Grab the liftgate motor assembly and lift upward and out to unhook the motor assembly from the D-pillar. 6. Remove the liftgate motor assembly from the vehicle. INSTALLATION 1. Using the motor housing tab, hook the liftgate motor assembly on the D-pillar. 2. Install the three motor assembly retaining bolts. Torque the two rear most bolts first to 9.5 Nm (85 in. lbs.). Torque the remaining bolt next to the window actuator to 9.5 Nm (85 in. lbs.). 3. Connect the liftgate motor assembly electrical connector. 4. Install the D-pillar trim panel on the vehicle. 5. Connect the battery negative cable. 6. Using an appropriate scan tool, check any erase any power liftgate control module diagnostic trouble codes related to the door motor assembly. 7. Verify power liftgate system operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Service and Repair > Engage Actuator > Page 9239 Trunk / Liftgate Motor: Service and Repair Lift Gear And Link Rod REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left rear D-pillar trim panel from the vehicle. Liftgate Gear Motor Assembly 3. Remove the lift gear retaining bolts. 4. Remove the lift gear and rod from the vehicle. INSTALLATION Liftgate Gear Motor Assembly Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Service and Repair > Engage Actuator > Page 9240 1. Position the lift gear and rod assembly and install the retaining bolts. Torque the bolts to 8 Nm (71 in. lbs.). 2. Install the D-pillar trim panel on the vehicle. 3. Connect the battery negative cable. 4. Using an appropriate scan tool, check any erase any power liftgate control module diagnostic trouble codes related to the door motor assembly. 5. Verify power liftgate system operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. CAUTION: Torque link rod to liftgate attachment bolt to 250 in. lbs. Care must be taken not to over-torque link rod bolt. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Service and Repair > Engage Actuator > Page 9241 Trunk / Liftgate Motor: Service and Repair Transverse Bracket REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left D-pillar trim from the vehicle. 3. Disconnect the gear motor assembly electrical connector and disengage retaining pushpin. 4. Loosen the gear motor assembly retaining bolts to allow room for transverse bracket to be removed. Liftgate Gear Motor Assembly 5. Remove the transverse bracket retaining bolts. 6. Remove the transverse bracket from the vehicle. INSTALLATION 1. Position the transverse bracket in the vehicle. Be certain the transverse bracket is properly positioned. The bracket should just touch the engage actuator arm and be positioned between the actuator arm and the motor housing. 2. Torque the transverse bracket retaining bolts to the gear motor assembly to 9.5 Nm (85 in. lbs.). Do not tighten the transverse bracket retaining bolt, located under the window actuator at this time. 3. Torque the gear motor assembly retaining bolts to 9.5 Nm (85 in. lbs.). 4. Torque the final transverse bracket retaining bolt to 9.5 Nm (85 in. lbs.). 5. Connect the gear motor assembly electrical connector and engage retaining pushpin. 6. Install the left D-pillar trim. 7. Connect the battery negative cable. 8. Using an appropriate scan tool, check any erase any power liftgate control module diagnostic trouble codes related to the door motor assembly. 9. Verify power liftgate system operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair Trunk / Liftgate Shock / Support: Service and Repair SUPPORT CYLINDER REMOVAL 1. Release liftgate latch and open liftgate. 2. Support liftgate on a suitable lifting device in the full open position. 3. Pull liftgate opening weatherstrip from D-pillar flange next to prop assembly end pivot. Fig. 5 4. Remove bolt attaching end pivot to D-pillar (Fig. 5). 5. Remove bolt attaching prop assembly to liftgate. 6. Remove prop assembly from vehicle. INSTALLATION Ensure that the cylinder end is attached to the D-pillar and the shaft end is attached to the liftgate. 1. Place prop assembly in position. 2. Install bolt attaching prop assembly to liftgate. 3. Install bolt attaching end pivot to D-pillar. Tighten bolts to 34 N.m (25 ft.lbs.) torque. 4. Install liftgate opening weatherstrip to D-pillar flange next to prop assembly end pivot. 5. Close liftgate. Check liftgate operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Stop > Component Information > Service and Repair Trunk / Liftgate Stop: Service and Repair SLAM BUMPER REMOVAL REMOVAL - BODY SIDE 1. Open liftgate. Fig. 8 2. Remove liftgate stop bumper body side attaching bolts (Fig. 8). 3. Remove liftgate stop bumper. REMOVAL - LIFTGATE SIDE 1. Open liftgate. 2. Remove liftgate stop bumper liftgate side attaching rivets by drilling out old rivets. 3. Remove liftgate stop bumper. INSTALLATION INSTALLATION - BODY SIDE 1. Place liftgate stop bumper into position. 2. Install bolts attaching liftgate stop bumper to body side (Fig. 8). 3. Close liftgate. INSTALLATION - LIFTGATE SIDE 1. Place liftgate stop bumper into position. 2. Install rivets attaching liftgate stop bumper to liftgate. NOTE: Verify that chips or parts of drilled out rivet does not rattle in the liftgate. If there is rattling sound, detrim liftgate and retrieve debris. 3. Close liftgate. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair Trunk / Liftgate Striker: Service and Repair LATCH STRIKER REMOVAL 1. Open liftgate. 2. Mark outline of striker on sill to aid installation. Fig. 3 3. Remove screws attaching striker to sill (Fig. 3). 4. Remove striker from vehicle. INSTALLATION 1. Place striker in position on vehicle. 2. Align striker to outline mark on sill. 3. Install screws attaching striker to sill. Tighten screws to 28 N.m (21 ft.lbs.) torque. 4. Verify liftgate alignment and operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Description and Operation > Exterior Handle Switch Trunk / Liftgate Switch: Description and Operation Exterior Handle Switch The exterior handle switch is an electronic release switch mounted to the rear license plate lamp housing assembly, located just above the license plate. This switch controls the power liftgate release function and is also capable of reversing the power lift-gate when it is in motion. A full power open cycle cannot be performed using this switch, only one of the power open command switches (key fob and overhead console mounted) can be used to perform a full power open cycle. The exterior handle switch is a serviceable component. When the exterior handle switch is depressed, with the liftgate in the closed position, a message is sent to the Body Control Module (BCM). The BCM then sends a signal to the power liftgate control module via the Programmable Communication Interface (PCI) data bus circuit. The power liftgate control module then sends a signal to the power latch mounted actuator, which moves the liftgate from the primary closed and latched position to the open and movable position. If the liftgate is not pulled open once the latch releases within a few seconds, the latch will cinch closed again. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Description and Operation > Exterior Handle Switch > Page 9255 Trunk / Liftgate Switch: Description and Operation Full Open Switch Full Open Switch Location The full open switch is located on the gear motor housing and is used to signal the power lift-gate control module when the power liftgate is in the full open position. Two wires are used from the full open switch contacts to the gear motor assemblies main electrical connector. The full open switch is a serviceable component. When the power liftgate reaches the full open position, the gear motor housing mounted full open switch electrical contacts close. This sends a ground signal to the power liftgate control module, telling the module that the liftgate has reached the full open position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Service and Repair > Exterior Handle Switch Trunk / Liftgate Switch: Service and Repair Exterior Handle Switch REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the liftgate and remove the liftgate trim panel. 3. Remove the rear lamp bar assembly from the vehicle. 4. Locate the two wires going to the exterior handle switch. Cut the tie strap and trace the wires to the large electrical connector and back the wires out of the large connector and through the grommet. Take care to mark the location of the wire terminals in relation to the large connector so that they are positioned in the appropriate cavities upon switch installation. Rear Light Bar 5. Depress the two exterior handle switch retaining tabs and roll the switch out of the light bar assembly. INSTALLATION Rear Light Bar 1. Install the handle switch in the light bar assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Service and Repair > Exterior Handle Switch > Page 9258 2. Locate the two wires going to the exterior handle switch. Install the wires through the grommet and in the large connector. Secure with a tie strap. NOTE: Be certain wires are reinstalled in the correct wire cavities. Failure to do so could result in damage to the handle switch. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. 3. Install the rear light bar. 4. Install the liftgate trim panel. 5. Connect the battery negative cable. 6. Using an appropriate scan tool, check any erase any power liftgate control module diagnostic trouble codes. 7. Verify power liftgate system and handle switch operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Service and Repair > Exterior Handle Switch > Page 9259 Trunk / Liftgate Switch: Service and Repair Full Open Switch REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lift gear and link rod assembly from the vehicle 3. Cut the two wires leading to the full open switch or back the wires out of the electrical connector. 4. Remove the full open switch retaining screw and remove the full open switch from the gear motor housing assembly. INSTALLATION 1. Perform a wiring repair on the full open switch wires following the approved procedure in the Wiring section. Or install new terminals on the wire ends and reinstall in the main lift-gate motor electrical connector. 2. Position and install the full open switch retaining screw. 3. Install the power liftgate lift gear and link rod assembly. 4. Connect the battery negative cable. 5. Using an appropriate scan tool, check any erase any power liftgate control module diagnostic trouble codes. 6. Verify power liftgate system and full open switch operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Exterior Name Plates - Tape Attached Body Emblem: Service and Repair Exterior Name Plates - Tape Attached EXTERIOR NAME PLATES -TAPE ATTACHED REMOVAL 1. Mark reference points before removing. 2. Using a heat gun gently apply heat in a circular motion to loosen the adhesive bond. 3. Using a nonmetallic prying device, such as a plastic or wood trim stick gently pry up at corners and remove. 4. Clean off all traces of adhesive or double sided tape from the panel with a general purpose adhesive remover. INSTALLATION 1. Clean panel surface with isopropyl alcohol. 2. Align badgeing to reference points. 3. Install and press securely to full adhesive contact 4. Clean away any reference points. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Exterior Name Plates - Tape Attached > Page 9265 Body Emblem: Service and Repair Exterior Name Plates - Adhesive Attached EXTERIOR NAME PLATES -ADHESIVE ATTACHED REMOVAL 1. Mark reference points before removing. 2. Using a heat gun gently apply heat in a circular motion to loosen the adhesive bond. 3. With your fingernail lift up and peel away badgeing/tape from panel, using a heat gun as you go. 4. Clean off all traces of adhesive from the panel(s) with a general purpose adhesive remover. INSTALLATION 1. Clean panel surface with isopropyl alcohol. 2. Remove paper carrier and align badgeing/tape to reference points or adjacent panel. 3. Install and press securely, using a plastic spreader to eliminate all air bubbles. 4. Remove top protective carrier. 5. Clean away any reference points. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE REMOVAL 1. Remove wiper arms. Fig. 6 2. Remove four (4) screws securing cowl cover to wiper module (Fig. 6). 3. Disengage quarter turn fasteners at outboard ends of cowl grill from body. 4. Release hood latch and open hood. CAUTION: To prevent hood scratching of cowl grille before removal, cover outboard exterior ends of cowl grille with masking tape or equivalent method. NOTE: Do not over bend cowl grille during removal. Bend cowl grille just enough to clear top of wiper pivot shaft and bottom rear corner of hood. 5. Remove cowl grill by raising above driver side wiper pivot shaft and swinging away towards engine compartment. The cowl grille will need to be bent on outboard end to clear simultaneously top of wiper pivot shaft and bottom corner of hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Page 9269 Fig. 7 6. Close hood. Do not latch. Remove outboard screws. (Fig. 7). 7. Disconnect washer hose in line connector. 8. Disconnect washer hose and grommet from hole in wiper module and pull out. 9. Remove cowl grille by raising over opposite wiper pivot shaft and removing away from vehicle. 10. Remove cowl cover from vehicle. INSTALLATION 1. Reverse removal procedure. 2. When installing cowl cover over wiper module, make sure fore aft locator on the underside of cowl grill seat into the locator grooves on top of wiper module. 3. Start all cowl grille mounting screws by hand before torquing to specifications. 4. Assure washer hose is properly routed and not pinched. 5. Center cowl grille to body and windshield. 6. Assure "arrow" indicator head of quarter turn fasteners is pointing toward windshield. 7. Tighten screw to 1.2 N.m (11 in.lbs.) torque. 8. Install the wiper arms. 9. Check for proper spray pattern from washer nozzles. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair Lower Side Moulding / Trim: Service and Repair BODY SIDE MOLDINGS REMOVAL Fig. 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Page 9273 Fig. 2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Page 9274 Fig. 3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Page 9275 Fig. 4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Service and Repair > Page 9276 Fig. 5 Refer to (Fig. 1), (Fig. 2), (Fig. 3), (Fig. 4) or (Fig. 5) for proper location of fasteners holding the molding to the wheelhouse lip and rocker panels. 1. Warm the affected stick on molding and body metal to approximately 38 degrees C (100 degrees F) using a suitable heat lamp or heat gun. 2. If equipped, remove pop rivets holding molding edge to wheelhouse lip. 3. Pull stick on molding from painted surface. 4. Remove adhesive tape residue from painted surface of vehicle. Use a 3M Scotch-Brite(TM) Molding Adhesive and Stripe Removal Disc, or equivalent, to clean adhesive residue from painted surfaces. These products are available from automotive paint suppliers. Refer to instructions supplied with the specific product for proper usage. INSTALLATION Refer to (Fig. 1), (Fig. 2), (Fig. 3), (Fig. 4) or (Fig. 5) for proper location of fasteners to hold the molding to the wheelhouse lip and rocker panels. 1. If molding is to be reused; a. Remove tape residue from molding. b. Clean back of molding with Mopar(R) Super Kleen, or equivalent. c. Wipe molding dry with lint free cloth. d. Apply a single coat of Mopar(R) TPO Molding Prep to tape side of molding and allow to dry thoroughly. e. Apply new body side molding (two sided adhesive) tape to back of molding. 2. Clean body surface with Mopar(R) Super Kleen, or equivalent. Wipe surface dry with lint free cloth. 3. Remove protective cover from tape on back of molding. 4. Apply molding to body from front to rear, inserting locator pins into hole in body panel. 5. Using a roller tool, roll molding onto body panel with enough force to assure adhesion. Do not apply excessive force, or damage to body panels may result. 6. Install pop rivets to hold molding edge to wheelhouse lip, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair FRONT WHEELHOUSE SPLASH SHIELD REMOVAL 1. Hoist and support vehicle on safety stands. 2. Remove front wheel. 3. Remove push pin fasteners attaching splash shield to frame rail forward of suspension. 4. Remove push pin fasteners attaching splash shield to frame rail rearward of suspension. 5. Remove screws attaching wheelhouse splash shield to front fender and front bumper fascia. Fig. 17 6. Remove splash shield from vehicle (Fig. 17). INSTALLATION 1. Place splash shield in position on vehicle (Fig. 17). 2. Install push pin fasteners attaching splash shield to frame rail forward of suspension. 3. Install push pin fasteners attaching splash shield to frame rail rearward of suspension. 4. Install screws attaching wheelhouse splash shield to front fender. 5. Install front wheel. 6. Lower vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Specifications Front Cross-Member: Specifications Front Cradle Crossmember Mounting Bolts (M14) ............................................................................................................................. 163 Nm (120 ft. lbs.) Front Cradle Crossmember Reinforcement Bolts M14 ...................................................................................................................................................... ............................................ 153 Nm (113 ft. lbs.) M12 ....................................................................... ............................................................................................................................. 106 Nm (78 ft. lbs.) M10 ...................................................................................................................................................... ................................................ 61 Nm (45 ft. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Specifications > Page 9287 Front Cross-Member: Description and Operation DESCRIPTION DESCRIPTION - FRONT CRADLE CROSSMEMBER This vehicle uses a one piece cast aluminum cradle for the front cradle crossmember. The cradle crossmember is used as the attaching points for the lower control arms, stabilizer bar and steering gear. The cradle also has the power steering hoses and the chassis brake tubes attached to it. WARNING: If a threaded hole in the suspension cradle needs to be repaired, only use the type of thread insert and installation procedure specified for this application. The threaded holes in the front cradle crossmember that are used for attachment of the lower control arm rear bushing retainer, power steering hose and chassis brake tubes can be repaired. The repair is done by the installation of a Heli-Coil(R) thread insert which has been specifically developed for this application. The procedure for installing the Heli-Coil(R) thread insert is detailed in the Service Procedures. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Procedures Front Cross-Member: Procedures DESCRIPTION - FRONT CRADLE CROSSMEMBER THREAD REPAIR WARNING: When performing this procedure use only the thread inserts which are specified in the Mopar Parts Catalog for this repair procedure. These thread inserts have been specifically developed for this application and use of other types of thread inserts can result in an inferior long term repair. The threaded holes in the front cradle crossmember, if damaged, can repaired by installing a Heli-Coil(R) thread insert. The threaded holes that are repairable using the thread insert, are the lower control arm rear bushing retainer mounting bolt holes, routing bracket attaching locations for the power steering hoses, and brake hose attachment holes. This repair procedure now allows the threaded holes in the cradle crossmember to be repaired, eliminating the need to replace the cradle crossmember if damage occurs to one of the threaded holes. The thread inserts for this application are specified by part number in the Mopar Parts Catalog. Do not use a substitute thread insert. The specific tools and equipment required to install the thread insert are listed below. Refer to the instructions included with the thread insert for the detailed procedure used for the installation of the thread insert. NOTE: The thread inserts for this application are for the repair of M8x1.25 and M10x1.5 threads. Be sure the correct tools are used for the required thread insert size. TOOL REQUIREMENT FOR M8x1.25 Thread - 8.3 mm (5/16 in.) Drill Bit - 120 degrees Countersink - Heli-Coil(R) Tap #4863-8 - Heli-Coil(R) Gage #4624-8 - Heli-Coil(R) Hand Inserting Tool 7751-8 - Needle Nose Pliers - For Removal Of Thread Insert Driving Tang TOOL REQUIREMENT FOR M10x1.5 Thread - 10.5 mm (25/64 in.) Drill Bit - 120 degrees Countersink - Heli-Coil(R) Tap #4863-10 - Heli-Coil(R) Gage #4624-10 - Heli-Coil(R) Hand Inserting Tool 7751-10 - Needle Nose Pliers - For Removal Of Thread Insert Driving Tang Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Procedures > Page 9290 Front Cross-Member: Removal and Replacement REMOVAL The front cradle crossmember must be installed in the design location to achieve proper front end suspension alignment. If the cradle crossmember is removed without applying reference marks on the frame rails, align the cradle crossmember according to the dimensions provided in this group. Fig. 20 NOTE: If the caged nuts in the frame rails become damaged and cannot be reused, a replacement nut can be obtained through Mopar(R) (Fig. 20). 1. Disconnect battery negative cable. 2. Remove steering column lower cover from instrument panel. 3. Remove steering column cover backing plate. Refer to Knee Diverter. 4. Position steering so front wheels are straight ahead. CAUTION: Do not rotate steering wheel after disengaging lower coupling from steering gear, damage to air bag clock spring can result. Fig. 21 5. Remove clinch bolt attaching steering column coupling to steering gear shaft (Fig. 21). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Procedures > Page 9291 6. Remove steering column coupling from telescoping steering gear shaft. 7. Hoist vehicle and support on safety stands. 8. Position a drain pan under power steering pump and oil return hose coupling. 9. Using a hose pinch-off pliers (C-4390), pinch power steering oil return hose off between the crossmember coupling and the pump. 10. Loosen hose clamp at the cradle crossmember coupling. 11. Disconnect return hose from metal tube. 12. While holding pressure relief valve nut on back of power steering pump, Remove flare nut attaching high pressure hose to back of pump. 13. Remove high pressure hose from pump. 14. Allow power steering fluid to drain into pan. 15. Remove bolts attaching anti-lock brake sensor leads to cradle crossmember. 16. Position anti-lock brake leads out of the way. 17. Disconnect stabilizer bar links from ends of stabilizer bar. 18. Disconnect lower ball joints from lower steering knuckles. Fig. 22 19. Remove the rear engine mount heat shield (Fig. 22). Fig. 23 20. Remove through bolt attaching rear engine mount to cradle crossmember (Fig. 23). 21. Using paint or grease pencil, mark outline of cradle crossmember on frame rails to aid installation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Procedures > Page 9292 Fig. 25 22. Support cradle crossmember on suitable lifting device (Fig. 25). Fig. 24 23. Remove bolts attaching crossmember to front frame rails (Fig. 24). 24. Remove cradle crossmember from vehicle (Fig. 25). INSTALLATION NOTE: If cradle crossmember requires replacement. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member > System Information > Service and Repair > Procedures > Page 9293 1. Support crossmember on suitable lifting device (Fig. 25). 2. Position crossmember to vehicle. 3. Loosely install bolts attaching cradle crossmember to front frame rails. 4. Place upper half of bushing on top of crossmember aligned to receive square tube protruding upward from lower bushing half. 5. Align crossmember to previously made marks on frame rails. 6. Tighten bolts attaching cradle crossmember to frame rails. 7. Install through bolt attaching rear engine mount to cradle crossmember (Fig. 23) and tighten to 68 N.m (50 ft.lbs.) torque. 8. Install the rear mount heat shield (Fig. 22). 9. Connect lower ball joints to steering knuckles. 10. Connect stabilizer bar links to ends of stabilizer bar. 11. Install bolts attaching anti-lock brake sensor leads to cradle crossmember. 12. Install high pressure hose to pump. 13. Connect return hose to metal tube. 14. Tighten hose clamp at the cradle crossmember coupling. 15. Remove pinch-off pliers. 16. Position steering so front wheels are straight ahead. 17. Install steering column coupling to telescoping steering gear shaft. 18. Install clinch bolt attaching steering column coupling to steering gear shaft. 19. Install steering column cover backing plate. 20. Install steering column lower cover from instrument panel. 21. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Front Cross-Member Bushing > System Information > Service and Repair Front Cross-Member Bushing: Service and Repair FRONT CROSSMEMBER MOUNT BUSHINGS REMOVAL 1. Using paint or grease pencil, mark outline of cradle crossmember on frame rails. 2. Loosen bolts attaching crossmember to frame rails. 3. Remove bolt on bushing that requires replacement. 4. Allow cradle crossmember to drop down enough to gain clearance for bushing removal. 5. Remove bushing from vehicle. INSTALLATION 1. Apply rubber lubrication or soap to replacement bushing. 2. Insert lower half of bushing into square hole in cradle crossmember. 3. Place upper half of bushing on top of crossmember aligned to receive square tube protruding upward from lower bushing half. 4. Squeeze bushing halves together to ensure they are properly mated. 5. Lift cradle crossmember upward to close gap between the bushing and frame. 6. Verify that lower bushing is fully seated into cradle crossmember and upper bushing. 7. Install bolt attaching bushing and crossmember to frame rail hand tight. 8. Align cradle crossmember to reference marks on frame rails. 9. Tighten cradle crossmember to frame rails attaching bolts to 163 N.m (120 ft.lbs.) torque. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Description and Operation Front Subframe: Description and Operation DESCRIPTION DESCRIPTION - FRONT CRADLE CROSSMEMBER This vehicle uses a one piece cast aluminum cradle for the front cradle crossmember. The cradle crossmember is used as the attaching points for the lower control arms, stabilizer bar and steering gear. The cradle also has the power steering hoses and the chassis brake tubes attached to it. WARNING: If a threaded hole in the suspension cradle needs to be repaired, only use the type of thread insert and installation procedure specified for this application. The threaded holes in the front cradle crossmember that are used for attachment of the lower control arm rear bushing retainer, power steering hose and chassis brake tubes can be repaired. The repair is done by the installation of a Heli-Coil(R) thread insert which has been specifically developed for this application. The procedure for installing the Heli-Coil(R) thread insert is detailed in the Service Procedures section in this group of the service manual. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Procedures Front Subframe: Procedures DESCRIPTION - FRONT CRADLE CROSSMEMBER THREAD REPAIR WARNING: When performing this procedure use only the thread inserts which are specified in the Mopar Parts Catalog for this repair procedure. These thread inserts have been specifically developed for this application and use of other types of thread inserts can result in an inferior long term repair. The threaded holes in the front cradle crossmember, if damaged, can repaired by installing a Heli-Coil(R) thread insert. The threaded holes that are repairable using the thread insert, are the lower control arm rear bushing retainer mounting bolt holes, routing bracket attaching locations for the power steering hoses, and brake hose attachment holes. This repair procedure now allows the threaded holes in the cradle crossmember to be repaired, eliminating the need to replace the cradle crossmember if damage occurs to one of the threaded holes. The thread inserts for this application are specified by part number in the Mopar Parts Catalog. Do not use a substitute thread insert. The specific tools and equipment required to install the thread insert are listed below. Refer to the instructions included with the thread insert for the detailed procedure used for the installation of the thread insert. NOTE: The thread inserts for this application are for the repair of M8x1.25 and M10x1.5 threads. Be sure the correct tools are used for the required thread insert size. TOOL REQUIREMENT FOR M8x1.25 Thread - 8.3 mm (5/16 in.) Drill Bit - 120 degrees Countersink - Heli-Coil(R) Tap #4863-8 - Heli-Coil(R) Gage #4624-8 - Heli-Coil(R) Hand Inserting Tool 7751-8 - Needle Nose Pliers - For Removal Of Thread Insert Driving Tang TOOL REQUIREMENT FOR M10x1.5 Thread - 10.5 mm (25/64 in.) Drill Bit - 120 degrees Countersink - Heli-Coil(R) Tap #4863-10 - Heli-Coil(R) Gage #4624-10 - Heli-Coil(R) Hand Inserting Tool 7751-10 - Needle Nose Pliers - For Removal Of Thread Insert Driving Tang Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Procedures > Page 9303 Front Subframe: Removal and Replacement REMOVAL The front cradle crossmember must be installed in the design location to achieve proper front end suspension alignment. If the cradle crossmember is removed without applying reference marks on the frame rails, align the cradle crossmember according to the dimensions provided in this group. Fig. 20 NOTE: If the caged nuts in the frame rails become damaged and cannot be reused, a replacement nut can be obtained through Mopar(R) (Fig. 20). 1. Disconnect battery negative cable. 2. Remove steering column lower cover from instrument panel. 3. Remove steering column cover backing plate. Refer to knee Diverter. 4. Position steering so front wheels are straight ahead. CAUTION: Do not rotate steering wheel after disengaging lower coupling from steering gear, damage to air bag clock spring can result. Fig. 21 5. Remove clinch bolt attaching steering column coupling to steering gear shaft (Fig. 21). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Procedures > Page 9304 6. Remove steering column coupling from telescoping steering gear shaft. 7. Hoist vehicle and support on safety stands. 8. Position a drain pan under power steering pump and oil return hose coupling. 9. Using a hose pinch-off pliers (C-4390), pinch power steering oil return hose off between the crossmember coupling and the pump. 10. Loosen hose clamp at the cradle crossmember coupling. 11. Disconnect return hose from metal tube. 12. While holding pressure relief valve nut on back of power steering pump, Remove flare nut attaching high pressure hose to back of pump. 13. Remove high pressure hose from pump. 14. Allow power steering fluid to drain into pan. 15. Remove bolts attaching anti-lock brake sensor leads to cradle crossmember. 16. Position anti-lock brake leads out of the way. 17. Disconnect stabilizer bar links from ends of stabilizer bar. 18. Disconnect lower ball joints from lower steering knuckles. Fig. 22 19. Remove the rear engine mount heat shield (Fig. 22). Fig. 23 20. Remove through bolt attaching rear engine mount to cradle crossmember (Fig. 23). 21. Using paint or grease pencil, mark outline of cradle crossmember on frame rails to aid installation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Procedures > Page 9305 Fig. 25 22. Support cradle crossmember on suitable lifting device (Fig. 25). Fig. 24 23. Remove bolts attaching crossmember to front frame rails (Fig. 24). 24. Remove cradle crossmember from vehicle (Fig. 25). INSTALLATION NOTE: If cradle crossmember requires replacement. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Procedures > Page 9306 1. Support crossmember on suitable lifting device (Fig. 25). 2. Position crossmember to vehicle. 3. Loosely install bolts attaching cradle crossmember to front frame rails. 4. Place upper half of bushing on top of crossmember aligned to receive square tube protruding upward from lower bushing half. 5. Align crossmember to previously made marks on frame rails. 6. Tighten bolts attaching cradle crossmember to frame rails. 7. Install through bolt attaching rear engine mount to cradle crossmember (Fig. 23) and tighten to 68 N.m (50 ft.lbs.) torque. 8. Install the rear mount heat shield (Fig. 22). 9. Connect lower ball joints to steering knuckles. 10. Connect stabilizer bar links to ends of stabilizer bar. 11. Install bolts attaching anti-lock brake sensor leads to cradle crossmember. 12. Install high pressure hose to pump. 13. Connect return hose to metal tube. 14. Tighten hose clamp at the cradle crossmember coupling. 15. Remove pinch-off pliers. 16. Position steering so front wheels are straight ahead. 17. Install steering column coupling to telescoping steering gear shaft. 18. Install clinch bolt attaching steering column coupling to steering gear shaft. 19. Install steering column cover backing plate. 20. Install steering column lower cover from instrument panel. 21. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe Mount > System Information > Service and Repair Front Subframe Mount: Service and Repair FRONT CROSSMEMBER MOUNT BUSHINGS REMOVAL 1. Using paint or grease pencil, mark outline of cradle crossmember on frame rails. 2. Loosen bolts attaching crossmember to frame rails. 3. Remove bolt on bushing that requires replacement. 4. Allow cradle crossmember to drop down enough to gain clearance for bushing removal. 5. Remove bushing from vehicle. INSTALLATION 1. Apply rubber lubrication or soap to replacement bushing. 2. Insert lower half of bushing into square hole in cradle crossmember. 3. Place upper half of bushing on top of crossmember aligned to receive square tube protruding upward from lower bushing half. 4. Squeeze bushing halves together to ensure they are properly mated. 5. Lift cradle crossmember upward to close gap between the bushing and frame. 6. Verify that lower bushing is fully seated into cradle crossmember and upper bushing. 7. Install bolt attaching bushing and crossmember to frame rail hand tight. 8. Align cradle crossmember to reference marks on frame rails. 9. Tighten cradle crossmember to frame rails attaching bolts to 163 N.m (120 ft.lbs.) torque. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair GRILLE DESCRIPTION Fig. 14 1. Front grille assembly (Fig. 14). REMOVAL 1. Remove front fascia, Refer to Front Bumper. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Page 9313 Fig. 15 2. Remove grille mounting spring clips (Fig. 15). 3. Remove grille INSTALLATION 1. Install grille to front fascia (Fig. 15). 2. Install front fascia to vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest Arm Rest: Service and Repair Armrest ARMREST REMOVAL Fig. 13 1. Using a small flat blade, pry cap from side of armrest (Fig. 13). 2. Remove bolt attaching armrest to seat back. 3. Remove armrest from seat back. INSTALLATION 1. Place armrest in position on seat back. 2. Install bolt attaching armrest to seat back. Tighten bolt to 29 N.m (21 ft.lbs.) torque. 3. Install side cap into the side of the armrest. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest > Page 9319 Arm Rest: Service and Repair Armrest - Sec Row - Stow - N - Go ARMREST - SEC ROW - STOW -N-GO REMOVAL Fig. 48 1. Remove armrest plug with a small flat bladed tool (Fig. 48). 2. Remove attaching screw. 3. Remove armrest from seat back. INSTALLATION 1. Place armrest into position (Fig. 48). 2. Install attaching screw. Tighten to 30 N.m (22 ft.lbs). 3. Install armrest plug. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest > Page 9320 Arm Rest: Service and Repair Armrest Rotating Assembly - Second Row - Stow - N - Go ARMREST ROTATING ASSEMBLY - SECOND ROW - STOW -N-GO REMOVAL 1. Remove headrest and headrest sleeves. 2. Remove both armrest. 3. Remove seat back panel. Fig. 49 4. Disengage J-strap from seat back (Fig. 49). 5. Move seat back cover and foam to access the armrest rotating assembly. Fig. 50 6. Remove armrest rotating assembly attaching screws (Fig. 50). 7. Remove armrest rotating assembly from the seat back frame. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Armrest > Page 9321 1. Place armrest rotating assembly into position (Fig. 50). 2. Install two armrest rotating assembly attaching screws. Tighten to 10 N.m (88 in.lbs). 3. Move seat back cover and foam to into proper position and engage J-straps (Fig. 49). 4. Install seat back panel. 5. Install both armrest. 6. Install headrest sleeves and headrest. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Customer Interest for Carpet: > 23-019-06 > May > 06 > Interior - Adhesive Residue On Carpet Carpet: Customer Interest Interior - Adhesive Residue On Carpet NUMBER: 23-019-06 GROUP: Body DATE: May 10, 2006 SUBJECT: Adhesive Residue From The Protective Covering On Carpeting MODELS: 2005 - 2006 (ND) Dakota 2005 - 2006 (LX) 300/Magnum/Charger 2005 - 2006 (RS) Town & Country/Caravan/Voyager PARTS REQUIRED: DISCUSSION: Occasionally when the protective covering is removed from the carpeting during new vehicle prep, an adhesive residue remains. Carpet replacement is not necessary as this residue is easily removed from the carpeting using Mopar(R) Super Kleen, p/n 04886330AB and a clean brush or cloth. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Carpet: > 23-019-06 > May > 06 > Interior - Adhesive Residue On Carpet Carpet: All Technical Service Bulletins Interior - Adhesive Residue On Carpet NUMBER: 23-019-06 GROUP: Body DATE: May 10, 2006 SUBJECT: Adhesive Residue From The Protective Covering On Carpeting MODELS: 2005 - 2006 (ND) Dakota 2005 - 2006 (LX) 300/Magnum/Charger 2005 - 2006 (RS) Town & Country/Caravan/Voyager PARTS REQUIRED: DISCUSSION: Occasionally when the protective covering is removed from the carpeting during new vehicle prep, an adhesive residue remains. Carpet replacement is not necessary as this residue is easily removed from the carpeting using Mopar(R) Super Kleen, p/n 04886330AB and a clean brush or cloth. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpets and Floor Mats Carpet: Service and Repair Carpets and Floor Mats CARPETS AND FLOOR MATS REMOVAL 1. Remove front seats. 2. Remove front center console. 3. Remove heel blocker (plastic block below accelerator pedal). 4. Remove the remaining seats. 5. Remove front cowl panels and sill plates. 6. Remove sliding door sill plates. Refer to Trim Panel. 7. Remove the cargo organizer, if equipped. 8. Remove liftgate scuff plate. Refer to Trim Panel. 9. Remove lower B-pillar trim covers. 10. Remove D-pillar trim covers. 11. Remove Quarter trim panels. Fig. 4 12. Remove floor escutcheons (Fig. 4). 13. Remove the floor console trays. 14. Remove push pin fasteners attaching carpet to floor in front seat and rear area. 15. Roll carpet from under instrument panel to center of sliding door. 16. Roll and fold carpet forward away from rear door opening. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpets and Floor Mats > Page 9337 Fig. 5 17. Extract carpet through sliding door opening (Fig. 5). INSTALLATION 1. Insert carpet through sliding door opening. 2. Roll carpet rearward toward rear door opening. 3. Roll carpet under instrument panel. 4. Install push pins fasteners through carpet and grommet into floor to attach carpet to floor in front seat area (Fig. 5). 5. Install push pins fasteners in the rear area. CAUTION: Ensure that the correct fasteners are installed in the proper locations. Damage to the fuel tank may result. 6. Install floor escutcheons (Fig. 4). 7. Install the floor console trays. 8. Install Quarter trim panels. 9. Install D-pillar trim covers. 10. Install lower B-pillar trim covers. 11. Install rear door sill plate. 12. Install sliding door sill plates. 13. Install front cowl panels and sill plates. 14. Install the passenger seats. 15. Install front center console. 16. Install heel blocker (plastic block below accelerator pedal). 17. Install front seats. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpets and Floor Mats > Page 9338 Carpet: Service and Repair Carpets - Fold - In - Floor CARPETS - FOLD - IN - FLOOR REMOVAL 1. Remove floor mats. 2. Remove front seats. 3. Remove instrument panel lower console. 4. Remove the floor console base tray and disconnect wire connector from the base tray. 5. Remove heel blocker (plastic block below accelerator pedal). Fig. 6 6. Remove winch plug (spare tire winch) (Fig. 6). 7. Remove front cowl panels and sill plates. 8. Remove kick plate and heel pad at gas pedal 9. Remove seat belt anchors at the passenger side B-pillar and driver side C-pillars 10. Fold in floor second and third row seats. Refer to the Owner's Manual for the proper procedures. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpets and Floor Mats > Page 9339 Fig. 7 11. Remove front carpet trim ring and cover (Fig. 7). Refer to Utility Storage Compartment. 12. Remove sliding door sill plates. Refer to Trim Panel. 13. Remove lower B-pillar trim covers. 14. Remove push pin fasteners attaching carpet to floor in front seat area. 15. Roll carpet from under instrument panel to center of sliding door. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpets and Floor Mats > Page 9340 Fig. 8 16. Pull carpet out from under the quarter trim panel (Fig. 8). Fig. 9 17. Using a trim stick, release clips attaching third row carpet cover, and remove (Fig. 9). 18. Remove rear carpet screws attaching rear of carpet. 19. Roll and fold carpet forward away from rear door opening. 20. Remove carpet through sliding door opening. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpets and Floor Mats > Page 9341 1. Place carpet through sliding door opening into position. 2. Roll carpet rearward towards the rear door opening. 3. Roll carpet forward under instrument panel (Fig. 8). 4. Install push pins fasteners through carpet and grommet into floor to attach carpet to floor in front seat area. 5. Pull wire harnesses through the carpet as needed. 6. Smooth out the carpet and allowing weld studs to go all the way through the carpet. 7. Install rear push pins fasteners attaching rear of carpet. 8. Place third row carpet cover into position and press clips into position (Fig. 9). 9. Slide the carpet under the quarter trim panel into position. 10. Install lower B-pillar trim covers. 11. Install sliding door sill plates. 12. Install front carpet trim ring and cover (Fig. 7). 13. Install seat belt anchors at the passenger side B-pillar and driver side C-pillars 14. Install kick plate and heel pad at the gas pedal 15. Install winch plug (spare tire winch) (Fig. 6). 16. Install front cowl panels and sill plates. 17. Install heel blocker (plastic block below accelerator pedal). 18. Install the floor console base tray and disconnect wire connector from the base tray. 19. Install instrument panel lower console. 20. Install front seats. 21. Install floor mats. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpets and Floor Mats > Page 9342 Carpet: Service and Repair Carpet Trim Ring and Cover - Fold - In - Floor CARPET TRIM RING AND COVER - FOLD - IN - FLOOR REMOVAL 1. Move front seats to the full forward position. 2. Fold the second row seats into the floor. Fig. 10 3. Remove the load floor plugs (Fig. 10). 4. Remove the ten weld nuts. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpets and Floor Mats > Page 9343 Fig. 11 5. Open door covers (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpets and Floor Mats > Page 9344 Fig. 12 6. Remove the four inter weld nuts (Fig. 12). 7. Raise the front trim ring and cover up off of the weld studs and remove from vehicle. INSTALLATION 1. Place front trim ring and cover assembly into position. 2. Open door covers (Fig. 11). 3. Install the four inter weld nuts (Fig. 12). 4. Close door covers. 5. Install the ten weld nuts (Fig. 10). 6. Install the eight load floor plugs. 7. Open the second row seats into position. 8. Move front seats to the position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpets and Floor Mats > Page 9345 Carpet: Service and Repair Rear Floor Tub Carpets Insert - Fold - In - Floor REAR FLOOR TUB CARPETS INSERT - FOLD - IN - FLOOR REMOVAL 1. Open liftgate. 2. Remove liftgate sill plate. Refer to Trim Panel. 3. Fold third row seats in to floor well. Fig. 40 4. Using a trim stick, unclip anchor molding (Fig. 40). 5. Remove two screws attaching front edge of floor tub carpet. 6. Fold seat back into the upright position. Fig. 41 7. Remove nuts attaching third row seat lower trim cover (Fig. 41) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpets and Floor Mats > Page 9346 Fig. 42 8. Lift rear tub carpet insert out of floor well (Fig. 42). 9. Remove tub insert from vehicle INSTALLATION 1. Place rear tub carpet insert into position on weld studs (Fig. 42). 2. Slip carpet edges under quarter trim panel. 3. Install nuts attaching third row seat lower trim cover (Fig. 41). Follow the tightening sequence. 4. Fold third row seats in to floor well. 5. Install two screws attaching front edge of floor tub carpet. 6. Place anchor molding into position push on clips to lock (Fig. 40). 7. Remove liftgate sill plate. 8. Close liftgate. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpets and Floor Mats > Page 9347 Carpet: Service and Repair Second Row Floor Tub Carpet Insert - Fold - In - Floor SECOND ROW FLOOR TUB CARPET INSERT - FOLD - IN -FLOOR REMOVAL 1. Move both front seats to the full forward position. 2. Fold second row seats into the floor well. 3. Remove rear carpet ring and cover from vehicle. Refer to Utility Storage Compartment. 4. Remove second row seat from vehicle. Repeat operation for other side, if necessary. Fig. 47 5. Remove second row floor tub insert(s) from vehicle (Fig. 47). INSTALLATION 1. Place second row floor tub insert(s) into position (Fig. 47). 2. Place seat(s) into position and install seat. Repeat operation for other side, if necessary. 3. Install rear carpet ring and cover position. 4. Open second row seats into the upright position. 5. Move both front seats to the normal position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lamp > Component Information > Diagrams Floor Console Lamp Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Console Lock Cylinder > Component Information > Service and Repair Console Lock Cylinder: Service and Repair FLOOR CONSOLE KEY LOCK TUMBLER - FOLD - IN - FLOOR REMOVAL 1. The key lock tumbler may be removed by depressing the tab on the lock cylinder with a stiff wire, to release the lock tumbler. 2. Pull key and lock tumbler from the lock cylinder. INSTALLATION 1. Place lock tumbler and key into the lock cylinder and push tumbler in until it lock into position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 9360 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 9361 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Page 9362 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair Drink Holders: Service and Repair REMOVAL 1. Remove the screw access cover from the bottom of the center bezel. 2. Remove the center bezel attaching screws. 3. Using a trim stick (special tool # C-4755) or equivalent, gently pry out on the edge of the instrument panel center bezel. Hang off to the side leaving the accessory switches connected. Tray Cup Holder 4. Pull the cup holder assembly rearward to disengage the rear guide studs from instrument panel. 5. Remove the cup holder assembly from lower instrument panel. INSTALLATION 1. Ensure the cup holder assembly is in the closed position. The cup holder assembly must be installed as an assembly to ensure proper track position. 2. Place the cup holder assembly into position in the lower instrument panel and slide into opening until the rear guide struts snap into place. 3. Install the center bezel. 4. Install the center bezel attaching screws 5. Install the screw access cover to the bottom of the center bezel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box Glove Compartment: Service and Repair Glove Box REMOVAL 1. Open glove box. 2. Push in on sides of glove box bin and lower door. 3. Pivot glove box downward and disengage hinge hooks from instrument panel. 4. Remove glove box. INSTALLATION 1. Place glove box in position. 2. Engage hinge hooks into instrument panel and pivot glove box upward. 3. Push in sides of glove box bin and snap glove box assembly into instrument panel. 4. Close glove box door. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box > Page 9370 Glove Compartment: Service and Repair Glove Box Latch Replacement REMOVAL 1. Open glove box. 2. Push in on sides of glove box bin and lower door. 3. Pivot glove box downward and disengage hinge hooks from instrument panel. 4. Remove glove box. 5. Remove the assembly screws. 6. Disassemble the glove box. 7. Separate the latch from the glove box assembly. INSTALLATION 1. Install the latch onto the glove box assembly. 2. Assemble the glove box. 3. Install the assembly screws. 4. Engage hinge hooks into instrument panel and pivot glove box upward. 5. Push in sides of glove box bin and snap glove box assembly into instrument panel. 6. Close glove box door. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Glove Box > Page 9371 Glove Compartment: Service and Repair Glove Box Latch Striker Replacement REMOVAL 1. Open glove box door. 2. Remove screws holding lock striker to instrument panel. 3. Remove glove box latch striker. INSTALLATION 1. Install the glove box latch striker. 2. Install the screws holding latch striker to instrument panel. 3. Close glove box door. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair HEADLINER REMOVAL 1. Remove sun visors and vanity mirrors. 2. Remove sun visor center supports. 3. Remove grab handles, if equipped. 4. If equipped, remove coat hooks. 5. If equipped, remove overhead rail console system. 6. Remove A-pillar trim covers. Refer to Trim Panel. Fig. 20 7. Remove B-pillar upper trim covers (Fig. 20). Refer to Trim Panel. Fig. 21 8. Remove C-pillar upper trim covers (Fig. 21). Refer to Trim Panel. 9. Remove D-pillar trim covers. Refer to Trim Panel. 10. Remove liftgate opening header trim. 11. If equipped, remove overhead console screws. 12. If equipped, remove reading lamps. 13. Remove dome lamp. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9375 Fig. 22 14. Remove push in locking fasteners attaching headliner to rear roof header and roof bows (Fig. 22). 15. Remove Overhead Rail Console System with DVD Player and related parts, if equipped. 16. Remove wiring connections. Fig. 23 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9376 Fig. 24 Fig. 25 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9377 Fig. 26 17. Remove headliner from roof. (Fig. 23) (Fig. 24) (Fig. 25) (Fig. 26). 18. Extract headliner through liftgate opening. Fig. 27 19. With the overhead rail system, second roof bow rail console bracket (Fig. 27). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9378 Fig. 28 20. With the overhead rail system, forth roof bow rail console bracket (2) (Fig. 28). INSTALLATION Fig. 29 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9379 Fig. 30 With overhead rail system, install second (Fig. 29) and/or forth (Fig. 30) roof bow console bracket(s), if necessary. Fig. 31 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9380 Fig. 32 Fig. 33 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9381 Fig. 34 1. Insert headliner through liftgate opening. (Fig. 31) (Fig. 32) (Fig. 33) (Fig. 34) 2. Place headliner in position on roof. 3. Connect wire connectors. Fig. 35 4. With the overhead rail system, ensure that wire connectors for the DVD player and the heater A/C control are position through the opening (Fig. 35). 5. Install left sun visor support. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9382 Fig. 36 6. Install push in locking fasteners attaching headliner to rear roof header and bows (Fig. 36). 7. Install right sun visor support. 8. Install sun visors and vanity mirrors. 9. If equipped, install roof rail modules. 10. If equipped, install coat hooks. 11. Install grab handles, if equipped. 12. Install dome lamp. 13. If equipped, install reading lamp. 14. If equipped, install overhead rail console system. 15. Install liftgate opening header trim. 16. Install D-pillar trim covers. Fig. 37 17. Install C-pillar upper trim covers (Fig. 37). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9383 Fig. 38 18. Install B-pillar upper trim covers (Fig. 38). 19. Install A-pillar trim covers. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > Assist Handle Passenger Assist Handle: Service and Repair Assist Handle ASSIST HANDLE REMOVAL 1. Using a trim stick (C-4755), remove screw access covers from grab-handle. 2. Remove screws holding grab-handle to roof rail. 3. Remove grab-handle from vehicle. INSTALLATION 1. Place grab-handle in position on vehicle. 2. Install screws to hold grab-handle to roof rail. 3. Install screw access covers into grab-handle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > Assist Handle > Page 9388 Passenger Assist Handle: Service and Repair Handle - Grab HANDLE - GRAB REMOVAL 1. Turn headlamp switch to shut off reading lamp. 2. Hold handle downward and remove attaching screws. Fig. 73 3. Pull handle inward to release handle clips from sheet metal (Fig. 73). 4. Disconnect wire connector from lamp, if equipped. 5. Remove grab handle from vehicle. INSTALLATION Fig. 74 1. Place grab handle into position (Fig. 74). 2. Connect lamp wire connector, if equipped. 3. Using 2-way locating pins press on grab handle until it snaps into place. 4. Install attaching screws. 5. Tug on handle to insure clips are properly installed. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > Assist Handle > Page 9389 Passenger Assist Handle: Service and Repair Front Seat Back Assist Strap FRONT SEAT BACK ASSIST STRAP REMOVAL Fig. 17 1. Using a small screw driver, pry screw plugs from ends of assist strap (Fig. 17). 2. Remove screws attaching assist strap to seat back. 3. Remove assist strap from vehicle. INSTALLATION 1. Place assist strap in position on vehicle. 2. Install screws attaching assist strap to seat back. Tighten screws to 7.0 N.m (60 in.lbs.). 3. Insert screw plugs into ends of assist strap (Fig. 17). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sun Visor Sun Visor: Service and Repair Sun Visor SUN VISOR REMOVAL All vehicles with driver and passenger side air bags must have a colored coded five Bullet point air bag warning label applied to the sun visor, verify label availability and ensure the label is installed. 1. Disengage sun visor from center support. Fig. 49 2. Remove screws attaching sun visor to roof header (Fig. 49). 3. Remove sun visor from roof. 4. If equipped, disconnect illuminated vanity mirror wire connector from body harness. 5. Remove sun visor from vehicle. INSTALLATION All vehicles with driver and passenger side air bags must have a colored coded five Bullet point air bag warning label applied to the sun visor, verify label availability and ensure the label is installed. 1. Place sun visor in position on vehicle. 2. Connect illuminated vanity mirror wire connector into body harness. 3. Place sun visor in position on roof. 4. Install screws to hold sun visor to roof header (Fig. 49). 5. Engage sun visor into center support. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Sun Visor > Page 9394 Sun Visor: Service and Repair Sun Visor Support SUN VISOR SUPPORT REMOVAL 1. Disengage sun visor from support. Fig. 50 2. Remove screw holding support to roof header (Fig. 50). 3. Remove sun visor support from vehicle. INSTALLATION 1. Place sun visor support in position on vehicle. 2. Install screw holding support to roof header (Fig. 50). 3. Engage sun visor into support. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical Service Bulletins > Customer Interest for Trim Panel: > 23-035-06 > Aug > 06 > Interior - Buzz/Rattle From Quarter Panel Speaker Area Trim Panel: Customer Interest Interior - Buzz/Rattle From Quarter Panel Speaker Area NUMBER: 23-035-06 GROUP: Body DATE: August 24, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-037-05, DATED AUGUST 18, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Buzz/Rattle Like Sound In Rear Quarter Panel Speaker Area With or Without The Radio On OVERVIEW: This bulletin involves cutting a tab off of the rear quarter trim panel so that the tab cannot contact the rear speaker grille on both sides of the vehicle. MODELS: 2005 - 2007 (RS) Town & Country/Caravan 2005 - 2007 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to vehicles built on or after June 1, 2004 (MDH 0601XX) through and including September 5, 2006 (MDH 0905XX). SYMPTOM/CONDITION: Buzz/Rattle like sound in the rear quarter panel speaker area with or without the radio on. DIAGNOSIS: If the Symptom/Condition is present, perform the Repair Procedure. REPAIR PROCEDURE: 1. Remove the left quarter trim bolster over the speaker. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body/Interior/Quarter Trim Bolster Removal. 2. Locate the tab on the quarter trim panel. Cut the tab off of the trim panel so that it cannot contact the speaker grille (Fig. 1). 3. Install the rear quarter trim bolster over the speaker. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical Service Bulletins > Customer Interest for Trim Panel: > 23-035-06 > Aug > 06 > Interior - Buzz/Rattle From Quarter Panel Speaker Area > Page 9403 4. Repeat Step #1 through Step #3 on the right side of the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trim Panel: > 23-035-06 > Aug > 06 > Interior - Buzz/Rattle From Quarter Panel Speaker Area Trim Panel: All Technical Service Bulletins Interior - Buzz/Rattle From Quarter Panel Speaker Area NUMBER: 23-035-06 GROUP: Body DATE: August 24, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-037-05, DATED AUGUST 18, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Buzz/Rattle Like Sound In Rear Quarter Panel Speaker Area With or Without The Radio On OVERVIEW: This bulletin involves cutting a tab off of the rear quarter trim panel so that the tab cannot contact the rear speaker grille on both sides of the vehicle. MODELS: 2005 - 2007 (RS) Town & Country/Caravan 2005 - 2007 (RG) Chrysler Voyager (International Markets) NOTE: This bulletin applies to vehicles built on or after June 1, 2004 (MDH 0601XX) through and including September 5, 2006 (MDH 0905XX). SYMPTOM/CONDITION: Buzz/Rattle like sound in the rear quarter panel speaker area with or without the radio on. DIAGNOSIS: If the Symptom/Condition is present, perform the Repair Procedure. REPAIR PROCEDURE: 1. Remove the left quarter trim bolster over the speaker. Refer to the detailed service information available in TechCONNECT, under: Service Info, 23 - Body/Interior/Quarter Trim Bolster Removal. 2. Locate the tab on the quarter trim panel. Cut the tab off of the trim panel so that it cannot contact the speaker grille (Fig. 1). 3. Install the rear quarter trim bolster over the speaker. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trim Panel: > 23-035-06 > Aug > 06 > Interior - Buzz/Rattle From Quarter Panel Speaker Area > Page 9409 4. Repeat Step #1 through Step #3 on the right side of the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim Trim Panel: Service and Repair Cowl Trim COWL TRIM REMOVAL 1. Remove door sill plate. Fig. 13 2. Disengage hidden clips holding cowl trim to cowl panel (Fig. 13). 3. Remove cowl trim from vehicle. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9412 Fig. 1 1. Place cowl trim panel in position on vehicle (Fig. 1). 2. Engage hidden clips attaching cowl trim to cowl panel. 3. Install door sill plate. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9413 Trim Panel: Service and Repair Door Sill Trim Panel DOOR SILL TRIM PLATE REMOVAL 1. Using trim stick (C-4755), disengage hidden clips holding door sill plate from door sill. Fig. 15 2. Remove sill plate from vehicle (Fig. 15). INSTALLATION 1. Place sill plate in position on vehicle (Fig. 15). 2. Align interlock tabs at front and rear to mating trim. 3. Engage hidden clips to hold door sill plate to door sill. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9414 Trim Panel: Service and Repair Front Door Trim Panel TRIM PANEL REMOVAL 1. Remove the plug and remove screw attaching door pull cup to inner door panel. 2. Remove switch bezel and disconnect power window/memory switch. 3. Remove screws attaching trim panel to door from below map pocket. 4. If equipped, remove window crank. 5. Remove screw holding door trim to door panel from behind inside latch release handle. 6. Disengage clips attaching door trim to door frame around perimeter of panel. 7. Lift trim panel upward to disengage flange from inner belt molding at top of door. 8. Tilt top of trim panel away from door to gain access to latch linkage. Fig. 22 9. Disengage clip attaching linkage rod to inside latch release handle (Fig. 22). 10. Separate linkage rod from latch handle. 11. Disconnect the power door switch, courtesy lamp electrical connectors. 12. Remove front door trim panel from vehicle. INSTALLATION 1. Hold top of trim panel away from door to gain access to latch linkage. 2. Place linkage rod in position on latch handle. 3. Engage clip to hold linkage rod to inside latch release handle. 4. Place front door trim panel in position on door. 5. Install trim panel into inner belt molding at top of door. 6. Install clips to attach door trim to door frame around perimeter of panel. 7. If equipped, install screw to attach door trim to door panel behind inside latch release handle. 8. If equipped, connect power switch into wire connector. 9. Place power accessary switch in position on door trim. 10. Connect wire connector into memory seat/mirror switch and install switch into trim panel. 11. Install screws to attach accessary switch panel to door trim. 12. Install screw cover into switch panel. 13. If equipped, install window crank. 14. If equipped, install screws to attach trim panel to door inside map pocket. 15. If equipped, install screw to attach door pull cup to inner door panel. 16. If equipped, install screws to attach door assist handle to inner door panel. 17. Connect wire connector into courtesy lamp. 18. Install lamp in door trim. 19. Install switch bezel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9415 Trim Panel: Service and Repair Liftgate Sill Scuff Plate LIFTGATE SILL PLATE REMOVAL Fig. 39 1. Disengage hidden clips holding sill plate to lift-gate door opening sill (Fig. 39). 2. Remove sill plate from vehicle. INSTALLATION 1. Place sill plate in position on vehicle. 2. Align engage hook tabs at end of liftgate sill plate to D-pillar trim. 3. Engage hidden clips to hold sill plate to liftgate door opening sill. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9416 Trim Panel: Service and Repair Cowl Trim COWL TRIM REMOVAL 1. Remove door sill plate. Fig. 13 2. Disengage hidden clips holding cowl trim to cowl panel (Fig. 13). 3. Remove cowl trim from vehicle. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9417 Fig. 1 1. Place cowl trim panel in position on vehicle (Fig. 1). 2. Engage hidden clips attaching cowl trim to cowl panel. 3. Install door sill plate. Door Sill Trim Panel DOOR SILL TRIM PLATE REMOVAL 1. Using trim stick (C-4755), disengage hidden clips holding door sill plate from door sill. Fig. 15 2. Remove sill plate from vehicle (Fig. 15). INSTALLATION 1. Place sill plate in position on vehicle (Fig. 15). 2. Align interlock tabs at front and rear to mating trim. 3. Engage hidden clips to hold door sill plate to door sill. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9418 Front Door Trim Panel TRIM PANEL REMOVAL 1. Remove the plug and remove screw attaching door pull cup to inner door panel. 2. Remove switch bezel and disconnect power window/memory switch. 3. Remove screws attaching trim panel to door from below map pocket. 4. If equipped, remove window crank. 5. Remove screw holding door trim to door panel from behind inside latch release handle. 6. Disengage clips attaching door trim to door frame around perimeter of panel. 7. Lift trim panel upward to disengage flange from inner belt molding at top of door. 8. Tilt top of trim panel away from door to gain access to latch linkage. Fig. 22 9. Disengage clip attaching linkage rod to inside latch release handle (Fig. 22). 10. Separate linkage rod from latch handle. 11. Disconnect the power door switch, courtesy lamp electrical connectors. 12. Remove front door trim panel from vehicle. INSTALLATION 1. Hold top of trim panel away from door to gain access to latch linkage. 2. Place linkage rod in position on latch handle. 3. Engage clip to hold linkage rod to inside latch release handle. 4. Place front door trim panel in position on door. 5. Install trim panel into inner belt molding at top of door. 6. Install clips to attach door trim to door frame around perimeter of panel. 7. If equipped, install screw to attach door trim to door panel behind inside latch release handle. 8. If equipped, connect power switch into wire connector. 9. Place power accessary switch in position on door trim. 10. Connect wire connector into memory seat/mirror switch and install switch into trim panel. 11. Install screws to attach accessary switch panel to door trim. 12. Install screw cover into switch panel. 13. If equipped, install window crank. 14. If equipped, install screws to attach trim panel to door inside map pocket. 15. If equipped, install screw to attach door pull cup to inner door panel. 16. If equipped, install screws to attach door assist handle to inner door panel. 17. Connect wire connector into courtesy lamp. 18. Install lamp in door trim. 19. Install switch bezel. Liftgate Sill Scuff Plate Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9419 LIFTGATE SILL PLATE REMOVAL Fig. 39 1. Disengage hidden clips holding sill plate to lift-gate door opening sill (Fig. 39). 2. Remove sill plate from vehicle. INSTALLATION 1. Place sill plate in position on vehicle. 2. Align engage hook tabs at end of liftgate sill plate to D-pillar trim. 3. Engage hidden clips to hold sill plate to liftgate door opening sill. A-Pillar Trim A - PILLAR TRIM REMOVAL 1. Remove the assist handle if equipped. Fig. 2 2. Disengage hidden clips holding A-pillar trim panel to A-pillar (Fig. 2). 3. Remove A-pillar trim from vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9420 INSTALLATION 1. Position foot on A-pillar trim panel into instrument panel top cover channel. 2. Position A-pillar trim in vehicle. 3. Align locator pins. 4. Engage hidden clips. 5. Install the assist handle, if equipped. A-Pillar Lower Extension Trim A - PILLAR LOWER EXTENSION TRIM REMOVAL 1. Remove instrument panel side cover. Fig. 1 2. Remove A-pillar extension trim from vehicle by disengaging hidden clips (Fig. 1). INSTALLATION 1. Place A-pillar extension trim in position on vehicle (Fig. 1). 2. Install instrument panel side cover. B-Pillar Lower Trim B - PILLAR LOWER TRIM REMOVAL NOTE: The driver's side a double ended stud is used. A nut has to be removed for the seat belt anchor removal and the stud for the retractor removal. NOTE: On the passenger side there is a belt tension sensor. 1. Slide lower seat belt cover rearward to expose anchor fastener. 2. Remove bolt/nut attaching lower seat belt anchor to floor. 3. Remove upper B-pillar trim cover. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9421 Fig. 3 4. Remove access panel from B-pillar trim (Fig. 3). 5. Disengage hidden clips attaching lower trim cover to B-pillar. 6. Remove lower B-pillar trim cover from vehicle. INSTALLATION NOTE: The driver's side a double ended stud is used. A nut has to be removed for the seat belt anchor removal and the stud for the retractor removal. NOTE: On the passenger side there is a belt tension sensor. 1. On the passenger side secure grommet to seat belt sensor connector into bottom of B-pillar lower trim prior to install B-pillar lower trim cover. 2. Place lower B-pillar trim cover in position on vehicle (Fig. 3). 3. Insert seat belt through hole in lower B-pillar trim. 4. Engage hidden clips attaching lower trim cover to B-pillar. 5. Install access cover. 6. Install upper B-pillar trim cover. 7. Place seat belt anchor in position on floor so webbing is pointed rearward and slightly outboard. 8. Install bolt/nut attaching lower seat belt anchor to floor. Tighten seat belt anchor bolt/nut to 39 N.m (29 ft.lbs.) torque. 9. Verify that seat belt anchor does not interfere with seat track travel. B-Pillar Upper Trim B - PILLAR UPPER TRIM REMOVAL 1. Remove bolt attaching lower seat belt anchor to floor. 2. Lower shoulder belt height adjuster to the bottom of travel. 3. Remove shoulder belt turning loop from height adjuster. 4. Use a Snap-on(R) Trim Pad Remover tool (A179A), or equivalent, and remove shoulder belt height adjuster knob. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9422 Fig. 3 5. Remove shoulder belt bezel from trim cover (Fig. 3). 6. Remove screw attaching trim cover to B-pillar from inside bezel cavity. 7. Disengage hidden clips attaching trim cover to B-pillar. 8. Remove B-pillar trim cover from vehicle. INSTALLATION 1. Insert seat belt through B-pillar trim and web guide (Fig. 3). 2. Place B-pillar trim cover in position on vehicle. 3. Engage hidden clips attaching trim cover to B-pillar. 4. Install shoulder belt bezel into trim cover. 5. Install height adjuster knob. 6. Install shoulder belt turning loop onto height adjuster. Tighten bolt to 39 N.m (29 ft.lbs.) torque. 7. Place seat anchor in position on floor so webbing is pointed rearward and slightly outboard or self aligning tab on passenger side. 8. Install bolt attaching lower seat belt anchor to floor. Tighten seat belt bolt to 39 N.m (29 ft.lbs.) torque. C-Pillar Trim C - PILLAR TRIM REMOVAL 1. Remove quarter trim panel. 2. Remove seat belt turning loop from height adjuster. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9423 Fig. 14 3. Remove screw attaching C-pillar trim panel to C-pillar (Fig. 14). 4. Disengage hidden clips attaching trim to upper C-pillar. 5. Remove upper C-pillar trim from vehicle. INSTALLATION 1. Place upper C-pillar trim in position on vehicle (Fig. 14). 2. Engage hidden clips attaching trim to upper C-pillar. 3. Install screw attaching C-pillar trim panel to C-pillar. 4. Install seat belt turning loop onto height adjuster. Tighten all seat belt bolts to 39 N.m (29 ft.lbs.) torque. 5. Install quarter trim panel. Left D-Pillar Trim Panel LEFT D - PILLAR TRIM PANEL REMOVAL 1. Remove rear header trim cover. 2. Remove liftgate sill plate. 3. Remove second row seat belt turning loop on long wheel base vehicle. 4. Remove bolt attaching second row seat belt lower anchor to quarter on short wheel base vehicle. 5. Disengage hidden clips attaching trim to D-pillar. 6. Disconnect speaker wire connector, if equipped. 7. Pass seat belt through slot in D-pillar trim panel on short wheel base vehicle. 8. Remove D-pillar trim from vehicle. INSTALLATION 1. Pass seat belt through slot in D-pillar trim panel on short wheel base vehicle. 2. Position D-pillar trim panel on vehicle. 3. Connect speaker wire connector to speaker, if equipped. 4. Align locating pins on backside of trim panel to mating holes in inner quarter panel. 5. Engage hidden clips attaching trim to D-pillar. 6. Install bolt attaching second row seat belt lower anchor to quarter on short wheel base vehicle. Tighten all seat belt bolts to 39 N.m (29 ft.lbs.). 7. Install second row seat belt turning loop on long wheel base vehicle. 8. Install liftgate sill plate. 9. Install rear header trim cover. Right D-Pillar Trim Panel RIGHT D PILLAR TRIM PANEL REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9424 1. Remove rear header trim cover. 2. Remove liftgate sill plate. 3. Remove second row seat belt turning loop on long wheel base vehicle. 4. Remove bolt attaching second row seat belt, anchor to quarter on short wheel base vehicle. 5. Disengage hidden clips attaching trim to D-pillar. 6. Remove D-pillar trim panel from D-pillar. 7. Disconnect speaker wire connector, if equipped. 8. Pass second row seat belt, if equipped, through slot in trim panel on short wheel base vehicle. 9. Remove D-pillar trim from vehicle. INSTALLATION 1. Position D-pillar trim on vehicle. 2. Pass second row seat belt, if equipped, through slot in trim panel on short wheel base vehicle. 3. Connect speaker wire connector to speaker, if equipped. 4. Align locating pins on backside of trim panel to mating holes in D-pillar. 5. Engage hidden clips attaching trim to D-pillar. 6. Install screws attaching trim panel to attaching bracket on short wheel base vehicle. 7. Install quarter trim bolster on short wheel base vehicle. 8. Install bolt to attach second row seat belt, if equipped, anchor to quarter on short wheel base vehicle. Tighten all seat belt bolts to 39 N.m (29 ft.lbs.) torque. 9. Install second row seat belt turning loop on long wheel base vehicle. 10. Install liftgate sill plate. 11. Install rear header trim cover. Left Quarter Trim Panel LEFT QUARTER TRIM PANEL REMOVAL CAUTION: Disconnect the negative cable clamp from battery post. Damage to accessory feed circuit can result. 1. Remove first row seat. 2. Remove second row seat, if equipped. 3. Remove front door sill plate on three door vehicle. 4. Remove sliding door sill plate on four door vehicle. 5. Remove left quarter trim bolster. 6. Remove C-pillar trim panel. 7. Remove left D-pillar trim panel. 8. Remove first row seat belt anchor. 9. Remove second row seat belt anchor on long wheel base vehicle. 10. Remove screws attaching quarter trim to quarter panel from bolster area. 11. Remove screws attaching rear edge of quarter trim to attaching bracket or inner quarter trim panel. 12. Disconnect wire connector from accessory power outlet, if equipped. 13. Remove quarter trim from quarter panel. 14. Pass front seat belt and turning loop through slot in quarter trim panel on three door vehicle. 15. Pass first row seat belt through slot in quarter trim panel. 16. Pass second row seat belt, if equipped, through slot in quarter trim panel on long wheel base vehicle. 17. Remove quarter trim panel from vehicle. INSTALLATION 1. Position quarter trim panel on vehicle. 2. Pass second row seat belt, if equipped, through slot in quarter trim panel on long wheel base vehicle. 3. Pass first row seat belt through slot in quarter trim panel. 4. Connect wire connector into accessory power outlet, if equipped. 5. Align locating pins on backside of trim panel to mating holes in inner panels. 6. Position quarter trim panel on inner quarter panel. 7. Install screws attaching rear edge of quarter trim to attaching bracket or inner quarter panel. 8. Install screws attaching quarter trim to inner quarter panel in bolster area. 9. Install second row seat belts anchor on long wheel base vehicle. Tighten all seat belt bolts to 39 N.m (29 in.lbs.) torque. 10. Install first row seat belt anchor. 11. Install left D-pillar trim panel. 12. Install C-pillar trim panel. 13. Install upper left B-pillar trim on three door vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9425 14. Install left quarter trim bolster. 15. Install front door sill plate on three door vehicle. 16. Install sliding door sill plate on four door vehicle. 17. Install second row seat, if equipped. 18. Install first row seat. 19. Connect the battery negative cable. Right Quarter Trim Panel RIGHT QUARTER TRIM PANEL REMOVAL CAUTION: Disconnect the battery negative cable. Damage to accessory feed circuit can result. 1. Remove first row seat. 2. Remove second row seat. 3. Remove sliding door sill trim panel. 4. Remove quarter trim bolster. 5. Remove D-pillar trim panel. 6. Remove first row seat belt anchor. 7. Remove second row seat belt anchor. 8. Remove screws attaching quarter trim to quarter panel from bolster area. 9. Remove screws attaching rear edge of quarter trim to attaching bracket. 10. Disengage hidden clips attaching front of quarter trim to quarter panel rearward of sliding door opening and at locators. 11. Remove quarter trim from quarter panel. 12. Disconnect speaker wire connector on LWB quarter trim panel with rear air conditioning. 13. Pass second row seat belt through slot in trim panel on long wheel base vehicle. 14. Pass first row seat belt through slot in trim panel. 15. Remove quarter trim panel from vehicle. INSTALLATION 1. Position quarter trim panel on vehicle. 2. Pass first row seat belt through slot in trim panel. 3. Pass second row seat belt through access hole in trim panel on long wheel base vehicle. 4. Connect wire connector into speaker on LWB with rear air conditioning. 5. Align locating pins on backside of trim panel to mating holes in inner quarter panel. 6. Engage hidden clips attaching front of quarter trim to quarter panel rearward of sliding door opening and at locators. 7. Install screws attaching rear edge of quarter trim to attaching bracket. 8. Install screws attaching quarter trim to inner quarter panel in bolster area. 9. Install second row seat belt anchor on long wheel base vehicle. Tighten all seat belt bolts to 39 N.m (29 ft.lbs.) torque. 10. Install first row seat belt anchor. 11. Install D-pillar trim panel. 12. Install C-pillar trim panel. 13. Install quarter trim bolster. 14. Install sliding door sill trim panel. 15. Install second row seat, if equipped. 16. Install first row seat. 17. Connect the battery negative cable. Quarter Trim Bolster QUARTER TRIM BOLSTER REMOVAL The speaker grille in the quarter trim panel is not removable. The trim panel must be removed to service the speaker. 1. Disengage hidden clips attaching trim bolster to quarter trim panel. 2. Remove quarter trim panel from vehicle. INSTALLATION The speaker grille in the quarter trim bolster is not removable. The trim bolster must removed to service the speaker. 1. Place quarter trim bolster in position on vehicle. 2. Engage hook retainer attaching front of trim bolster to quarter trim panel, if applicable. 3. Engage hidden clips attaching trim bolster to quarter trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9426 Rear Header Trim REAR HEADER TRIM REMOVAL Fig. 43 1. Disengage hidden clips holding trim to rear header (Fig. 43). 2. Separate rear header trim from vehicle. INSTALLATION 1. Place rear header trim in position on vehicle. 2. Align guide pins on trim to holes in header. 3. Engage hidden clips to hold trim to rear header. 4. Engage interlock tabs at D-pillar trim. Rear HVAC Louver REAR HVAC LOUVER REMOVAL 1. Using a trim stick (C-4755), pry edge of louver from bezel. 2. Remove HVAC louver from bezel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9427 Fig. 44 3. Using a trim stick, pry lower edge of HVAC bezel away from headlining (Fig. 44). 4. Remove louver from vehicle. INSTALLATION 1. Place bezel in position in HVAC duct opening. 2. Push inward on bezel until clips snap in place. Verify that all four clips have been engaged to the bezel and that the bezel is flush to the headlining 3. Position HVAC louver to bezel. 4. Snap both ends of the louver into HVAC bezel. Sliding Door Sill Plate SLIDING DOOR SILL PLATE REMOVAL 1. Disengage hidden clips holding sill plate to sliding door opening sill. Fig. 48 2. Disengage hooks holding outside edge of sill plate to door sill (Fig. 48). 3. Remove sill plate from vehicle. INSTALLATION 1. Place sill plate in position on vehicle. 2. Engage hooks to hold outside edge of sill plate to door sill. 3. Align guide pins to holes in door sill. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Cowl Trim > Page 9428 4. Engage hidden clips to hold sill plate to sliding door opening sill. 5. Engage interlock tabs at lower B-pillar and quarter trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage Compartment Handle > Component Information > Service and Repair Utility Storage Compartment Handle: Service and Repair SECOND ROW DOOR COVER HANDLE AND EMERGENCY RELEASE REMOVAL Fig. 51 1. Raise second row door cover (Fig. 51). Fig. 52 2. Attach to the handle is a emergency release strap (Fig. 52). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage Compartment Handle > Component Information > Service and Repair > Page 9433 Fig. 53 3. Remove two screws attaching the handle cover (Fig. 53). Fig. 54 4. Remove handle cover and disengage the emergency release strap (Fig. 54). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage Compartment Handle > Component Information > Service and Repair > Page 9434 Fig. 55 5. Move emergency release strap towards center of vehicle and disengage strap (Fig. 55). 6. Remove handle and emergency release strap from vehicle. INSTALLATION 1. Place emergency release strap into position. Fig. 56 2. Move emergency release strap outward and to engage strap. (Fig. 56) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage Compartment Handle > Component Information > Service and Repair > Page 9435 Fig. 57 3. Engage the emergency release strap and handle cover over handle latch (Fig. 57). Fig. 58 4. Install two screws attaching the handle cover (Fig. 58). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage Compartment Handle > Component Information > Service and Repair > Page 9436 Fig. 59 5. Close second row door cover (Fig. 59). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Utility Storage Compartment > Utility Storage Compartment Latch > Component Information > Service and Repair Utility Storage Compartment Latch: Service and Repair UNDER SEAT STORAGE BIN LOCK/LATCH REMOVAL 1. Open under seat storage bin. Fig. 100 2. Remove screws holding under seat storage bin lock/latch to storage bin (Fig. 100). 3. Remove lock/latch from bin. INSTALLATION 1. Place lock/latch in position on storage bin. 2. Install screws to hold lock/latch to storage bin (Fig. 100). 3. Verify under seat storage bin latch operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Sliding Door Lock Knob > Component Information > Service and Repair Sliding Door Lock Knob: Service and Repair BELLCRANK REMOVAL 1. Remove stop bumper. 2. Remove sliding door trim panel. 3. Peel watershield away from adhesive around perimeter of inner door panel as necessary to gain access to latch bellcrank. Fig. 23 4. Disengage lock link (Fig. 23). 5. Disengage link and sleeve 6. Remove bellcrank by rotating bellcrank to release it from door. 7. Remove bellcrank from vehicle. INSTALLATION 1. Position bellcrank on vehicle. 2. Rotate bellcrank into position. 3. Place lock link into position and engage clip (Fig. 23). 4. Place link and sleeve into position and engage clip. 5. Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages. 6. Install sliding door trim panel. 7. Install stop bumper. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Sliding Door Hold-Open Latch > Component Information > Description and Operation Sliding Door Hold-Open Latch: Description and Operation Removing/Installing Power Latch In Sliding Door One power latch is used for each power sliding door. The latch is located on the trailing edge of the sliding door assembly. This power latch assembly is comprised of many different components which have the ability to perform the power cinch, release, lock, unlock and safety related operations. These components are the door latch, lock/unlock actuator, cinch/release actuator and child lockout, pawl, ratchet and handle switches. The pawl and ratchet switches are used to indicate the primary and secondary latched positions. The cinch latch also provides a connection point for the interior handle, exterior handle and hold open latch cables. If any of the components of the latch assembly are inoperative the complete power latch assembly must be replaced. The power latch performs the same operation as a full manual door latch as well as power cinch, release, lock and unlock operations. The power latch mounted actuator cinches the door closed and latches it in its primary latched position. During a power close cycle, the power cinch actuator will not operate until the power sliding door has reached its secondary latch position (determined by pawl and ratchet switches). During a power open cycle, the power release actuator will stop once the sliding door has moved from the primary latch position. The power latch uses inputs from the lock/unlock actuator, power sliding door control module and child lockout, pawl, ratchet and handle switches to provide safe power cinch and release operations. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Sliding Door Hold-Open Latch > Component Information > Service and Repair > Procedures Sliding Door Hold-Open Latch: Procedures REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the appropriate side door trim panel. 3. Remove the weather shield if necessary. Removing Latch Retaining Bolts 4. Open the side door all the way and remove the door latch retaining bolts. Power Latch Position And Orientation 5. Partially close the door and pull the latch assembly out of the side door inner panel. 6. Disconnect all electrical connectors leading to the latch assembly. 7. Disconnect the inside and outside handle cables from the latch assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Sliding Door Hold-Open Latch > Component Information > Service and Repair > Procedures > Page 9450 8. Disconnect the hold open latch cable from the latch assembly. 9. Disconnect lock actuator link rod from the latch assembly. 10. Remove the latch assembly from the vehicle. INSTALLATION Power Latch Position And Orientation 1. Position the latch assembly in the vehicle. Be certain all latch mounted components are installed on the replacement latch assembly. If not, transfer components from the old latch to the new latch assembly. 2. Connect the lock actuator link rod on the latch assembly. 3. Connect the hold open latch cable on the latch assembly. 4. Connect the inside and outside handle cables on the latch assembly. 5. Connect all electrical connectors leading to the latch assembly. Removing Latch Retaining Bolts Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Sliding Door Hold-Open Latch > Component Information > Service and Repair > Procedures > Page 9451 6. With assistance from another person, position the side door and install the door latch retaining bolts. Torque to 10 - 12 Nm (100 in. lbs.). 7. Install the weathershield if necessary. 8. Install the appropriate side door trim panel. 9. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Sliding Door Hold-Open Latch > Component Information > Service and Repair > Procedures > Page 9452 Sliding Door Hold-Open Latch: Removal and Replacement Hold Open Latch HOLD OPEN LATCH REMOVAL 1. Open sliding door. 2. Remove sliding door sill plate. Refer to Trim Panel. Fig. 2 3. Remove nuts attaching hold open latch to lower roller arm (Fig. 2). 4. Remove hold open latch from lower arm. 5. Disconnect cable from hold open latch. 6. Remove hold open latch from vehicle. INSTALLATION 1. Place hold open latch in position on vehicle. 2. Connect cable to hold open latch. 3. Place hold open latch in position on lower arm. 4. Install nuts attaching the hold open latch to lower roller arm. Tighten nuts to 5 N.m (45 in.lbs.) torque. 5. Install sliding door sill plate. 6. Verify sliding door operation. Hold Open Latch Cable HOLD OPEN LATCH CABLE REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the appropriate side door trim panel from the vehicle. 3. Peel watershield away from adhesive around perimeter of inner door panel. 4. Open the side door and remove the latch assembly. CAUTION: Make note of cable routing and foam insulator placement. This will prove helpful when reinstalling replacement cable. Be certain replacement cable is routed and retained correctly. 5. Trace the hold open latch cable along its routing path and disconnect from its retaining clips. 6. Disconnect the hold open latch cable from the latch assembly. Gently pry cable sleeve retainer out of the latch mounting bracket and then unhook swedged cable end from the latch link. 7. Remove the hold open latch from the side door. 8. Disconnect the hold open latch cable from the hold open latch. Gently pry cable sleeve retainer out of the handle bracket and then unhook swedged cable end from the latch link. 9. Remove the hold open latch cable from the side door. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Sliding Door Hold-Open Latch > Component Information > Service and Repair > Procedures > Page 9453 INSTALLATION 1. Match the replacement cable up against the old cable to verify the correct part. 2. Position the hold open latch cable on the side door. NOTE: The hold open latch cable is marked with white tape. It must be attached to the upper most cable attachment at the latch. This position is marked with a "W" on the latch. 3. Connect the hold open latch cable on the hold open latch assembly. Hook the swedged cable end on the latch link and gently push the cable sleeve retainer in the latch bracket. 4. Install the hold open latch on the side door. 5. Connect the hold open latch cable on the latch assembly. Hook the swedged cable end on the latch link and gently push the cable sleeve retainer in the latch bracket. 6. Trace the outside handle cable along its routing path and install on its retaining clips and position foam insulators. Use previously made schematic as a guide or remove the opposite side door trim panel and use that door as a guide. CAUTION: Be certain replacement cable is routed and retained correctly and foam insulators are properly positioned. 7. Install the latch assembly. 8. Place the watershield into position and press securely to adhesive making sure to properly route wiring and linkages. 9. Install the appropriate side door trim panel on the vehicle. 10. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair Door Lock Cylinder: Service and Repair LOCK CYLINDER REMOVAL 1. Roll door glass up. 2. Remove front door watershield as necessary to gain access to the outside door handle. Refer to Front Door Panel. 3. Through access hole at rear of inner door panel, disconnect Vehicle Theft Security System (VTSS) switch connector from door harness, if equipped. 4. Disengage push in fasteners attaching VTSS switch harness to inner door reinforcement bar, if equipped. Fig. 21 5. Disengage clip holding door latch linkage to door latch (Fig. 21). 6. Remove latch linkage from latch. 7. Disengage clip holding door lock linkage to door latch. 8. Remove lock linkage from latch. 9. Remove nuts attaching outside door handle to door outer panel. 10. Remove outside door handle from vehicle. 11. Disengage clip holding lock cylinder into outside handle. 12. Pull lock cylinder from door handle. INSTALLATION 1. Engage clip into outside handle to hold lock cylinder (Fig. 21). 2. With link arm toward rear of vehicle, push lock cylinder into door handle until clip snaps into place. 3. Insert lock linkage into door latch. 4. Engage clip to hold door lock linkage to latch. 5. Insert latch linkage into door latch. 6. Engage clip to hold door latch linkage to latch. 7. Install push in fasteners attaching VTSS switch harness to inner door reinforcement bar, if equipped. 8. Connect VTSS switch connector into door harness, if equipped. 9. Verify door latch operation. 10. Install watershield and door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder Switch > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder Switch > Component Information > Locations > Page 9460 Left Cylinder Lock Switch (EXport) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder Switch > Component Information > Locations > Page 9461 Door Lock Cylinder Switch: Description and Operation The Door Cylinder Lock Switch (If equipped) is used to: - Unlock/Lock all the doors via the Central Locking feature. - Arm/Disarm the Vehicle Theft Security System. - Trigger the Illuminated Entry feature. The door cylinder lock switch is mounted to the rear of the driver door lock cylinder. When installed on the rear of the cylinder, there is a tab on the lock cylinder that aligns with the switch to prevent it from turning. An anti-rotating device. The door cylinder lock switch is a one time use switch. Once it is removed from the rear of the door lock cylinder, it may not be reinstalled and a new switch must be used. When the Door Cylinder Lock Switch is turned either way using the door key cylinder, the BCM reads a direct message signal from the switch. If turning the key cylinder once, toward the front of the vehicle, this will: 1. Mechanically unlock the door lock. 2. Disarm the Vehicle Theft Security System (if equipped). 3. Turn on the Illuminated Entry (if equipped) for approximately 30 seconds. If the key cylinder is turned to the unlock position (toward the front of vehicle) twice within two seconds, all the doors and liftgate will unlock (if equipped with the central locking feature). To lock the vehicle using the door cylinder lock switch, turn the key cylinder toward the rear of the vehicle once. This will lock the door that you are using the key on. If equipped with the central locking feature, this will lock all the other doors and liftgate. Furthermore, this will arm the vehicle theft security system and turn off the illuminated entry. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder Switch > Component Information > Locations > Page 9462 Door Lock Cylinder Switch: Testing and Inspection Door Cylinder Lock Switch Resistance Any diagnosis of the power lock system should begin with the use of the DRB III (R) diagnostic tool. 1. Visually inspect the switch for proper installation. Make sure it is seated on the rear of the key cylinder, with the tab of the door key cylinder properly aligned with the slot on the door cylinder lock switch. 2. Disconnect the switch at the harness connector and check the resistance in each switch position. CAUTION: Do not disconnect the switch from the rear of the door key cylinder. This switch is a one time use switch. Once it is removed from the rear of the switch, it is not reusable and must be replaced. Test the switch at the harness connector. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder Switch > Component Information > Locations > Page 9463 Door Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel of the effected door cylinder lock switch. 3. Close the door window. 4. Disconnect the door cylinder lock switch wire connector from the door harness, and wiring clip from the impact beam. 5. Remove the outer door handle from the door. 6. Remove the switch from the key cylinder in the door handle and remove from vehicle. INSTALLATION 1. Install the switch on the key cylinder in the door handle. 2. Install the door handle. 3. Connect the door cylinder lock switch wire connector to the door harness, and the wiring clip to the impact beam. 4. Install the door trim panel of the affected door cylinder lock switch. 5. Connect the battery negative cable. 6. Verify system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations > Page 9469 Keyless Entry Module: Connector Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations > Page 9470 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations > Page 9471 Steering Column Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations > Page 9472 Center Instrument Panel Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Component Locations > Page 9473 Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 9474 Sentry Key Remote Entry Module (Skreem) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 9475 Keyless Entry Module: Description and Operation The Sentry Key Remote Entry Module (SKREEM) performs the functions of the Sentry Key Immobilizer Module (SKIM), Remote Keyless Entry (RKE) Module, and the Tire Pressure Monitoring (TPM) System (previously part of the Electronic Vehicle Information Center (EVIC). The SKREEM is located in the same location as the SKIM was and is mounted the same way. It looks identical, but has added capabilities. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 9476 Keyless Entry Module: Testing and Inspection For proper diagnosis and testing of the Sentry Key Remote Entry Module (SKREEM), use a DRBIII (R) and refer to the proper Body Diagnostic Procedures information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 9477 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the Steering Column Opening Cover. 3. Remove the steering column upper and lower shrouds. 4. Disengage the steering column wire harness from the Sentry Key Remote Entry Module (SKREEM). 5. Remove the one screws securing the SKREEM to the steering column. 6. Rotate the SKREEM upwards and then to the side away from the steering column to slide the SKREEM antenna ring from around the ignition switch lock cylinder housing. 7. Remove the SKREEM from the vehicle. INSTALLATION 1. Slip the Sentry Key Remote Entry Module (SKREEM) antenna ring around the ignition switch lock cylinder housing. Rotate the SKREEM downwards and then towards the steering column. 2. Install the one screws securing the SKREEM to the steering column. 3. Connect the steering column wire harness to the SKREEM. 4. Install the steering column upper and lower shrouds. 5. Install the Steering Column Opening Cover. 6. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Specifications Keyless Entry Transmitter Battery: Specifications BATTERY The batteries can be removed without special tools and are readily available at local retail stores. The recommended battery is Duracell DL 2016 or equivalent, TWO cells are required. Battery life is about three years minimum. CAUTION: Do not touch the battery terminals or handle the batteries any more than necessary. Hands must be clean and dry. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Specifications > Page 9482 Keyless Entry Transmitter Battery: Service and Repair BATTERY REPLACEMENT 1. With the transmitter buttons facing down, use a coin to pry the two halves of the transmitter apart. Make sure not to damage the rubber gasket during separation of the housing halves. 2. Remove the battery from the transmitter back housing holder. 3. Replace the batteries. Avoid touching the new batteries with your fingers, Skin oils may cause battery deterioration. If you touch a battery, clean it off with rubbing alcohol. 4. To assemble the transmitter case, snap the two halves together. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Cylinder Switch > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Cylinder Switch > Component Information > Locations > Page 9487 Left Cylinder Lock Switch (EXport) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Cylinder Switch > Component Information > Locations > Page 9488 Door Lock Cylinder Switch: Description and Operation The Door Cylinder Lock Switch (If equipped) is used to: - Unlock/Lock all the doors via the Central Locking feature. - Arm/Disarm the Vehicle Theft Security System. - Trigger the Illuminated Entry feature. The door cylinder lock switch is mounted to the rear of the driver door lock cylinder. When installed on the rear of the cylinder, there is a tab on the lock cylinder that aligns with the switch to prevent it from turning. An anti-rotating device. The door cylinder lock switch is a one time use switch. Once it is removed from the rear of the door lock cylinder, it may not be reinstalled and a new switch must be used. When the Door Cylinder Lock Switch is turned either way using the door key cylinder, the BCM reads a direct message signal from the switch. If turning the key cylinder once, toward the front of the vehicle, this will: 1. Mechanically unlock the door lock. 2. Disarm the Vehicle Theft Security System (if equipped). 3. Turn on the Illuminated Entry (if equipped) for approximately 30 seconds. If the key cylinder is turned to the unlock position (toward the front of vehicle) twice within two seconds, all the doors and liftgate will unlock (if equipped with the central locking feature). To lock the vehicle using the door cylinder lock switch, turn the key cylinder toward the rear of the vehicle once. This will lock the door that you are using the key on. If equipped with the central locking feature, this will lock all the other doors and liftgate. Furthermore, this will arm the vehicle theft security system and turn off the illuminated entry. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Cylinder Switch > Component Information > Locations > Page 9489 Door Lock Cylinder Switch: Testing and Inspection Door Cylinder Lock Switch Resistance Any diagnosis of the power lock system should begin with the use of the DRB III (R) diagnostic tool. 1. Visually inspect the switch for proper installation. Make sure it is seated on the rear of the key cylinder, with the tab of the door key cylinder properly aligned with the slot on the door cylinder lock switch. 2. Disconnect the switch at the harness connector and check the resistance in each switch position. CAUTION: Do not disconnect the switch from the rear of the door key cylinder. This switch is a one time use switch. Once it is removed from the rear of the switch, it is not reusable and must be replaced. Test the switch at the harness connector. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Cylinder Switch > Component Information > Locations > Page 9490 Door Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel of the effected door cylinder lock switch. 3. Close the door window. 4. Disconnect the door cylinder lock switch wire connector from the door harness, and wiring clip from the impact beam. 5. Remove the outer door handle from the door. 6. Remove the switch from the key cylinder in the door handle and remove from vehicle. INSTALLATION 1. Install the switch on the key cylinder in the door handle. 2. Install the door handle. 3. Connect the door cylinder lock switch wire connector to the door harness, and the wiring clip to the impact beam. 4. Install the door trim panel of the affected door cylinder lock switch. 5. Connect the battery negative cable. 6. Verify system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Component Locations Power Door Lock Actuator: Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Component Locations > Page 9495 Power Door Lock Actuator: Connector Locations Driver Door Passenger Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Component Locations > Page 9496 Right Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 9497 Power Door Lock Actuator: Diagrams Left Front Door Lock Motor/Ajar Switch (Except Base) Left Sliding Door Lock Motor (Power Sliding Door) Left Sliding Door Lock Motor/Ajar Switch (Manual Sliding Door) Right Front Door Lock Motor/Ajar Switch (Except Base) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 9498 Right Sliding Door Lock Motor (Power Sliding Door) Right Sliding Door Lock Motor/Ajar Switch (Manual Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 9499 Power Door Lock Actuator: Testing and Inspection Any diagnosis of the power lock system should begin with the use of the DRB III (R) diagnostic tool. For information on the use of the DRB III (R). For complete circuit diagrams, refer to the appropriate wiring information. Verify battery condition before testing door lock motor(s). To determine which motor is faulty, check each individual door for electrical lock and unlock or disconnect the motor connectors one at a time, while operating the door lock switch. In the event that none of the motors work, the problem may be caused by a shorted motor or a faulty switch. Disconnecting the faulty motor will allow the others to work. To test an individual door lock motor, disconnect the electrical connector from the motor. To lock the door, connect a fused 12 volt power source to the positive pin of the lock motor and a ground wire to the other pin. To unlock the door reverse the wire connections at the motor pin terminals. If these results are not obtained, replace the door latch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Page 9500 Power Door Lock Actuator: Service and Repair SLIDING DOOR LOCK MOTOR REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove sliding door trim panel. 3. Remove sound pad as necessary. 4. Remove latch/lock control cover. 5. Remove latch/lock control. Sliding Door Lock Motor 6. Remove screws holding door lock motor to latch/lock control. 7. Remove lock motor from control. INSTALLATION 1. Position the lock motor on the latch/lock. 2. Install the screws retaining the motor to the latch/lock. 3. Install the latch/lock control. 4. Install the latch/lock control cover. 5. Install the sound pad and trim panel to the sliding door. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Component Locations Power Door Lock Switch: Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Component Locations > Page 9505 Passenger Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 9506 Power Door Lock Switch: Diagrams Driver Door Lock Switch Passenger Door Lock Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 9507 Power Door Lock Switch: Testing and Inspection Door Lock Switch Continuity 1. Remove door trim panel. 2. Disconnect wire connector from back of door lock switch. 3. Depress switch to LOCK position. Door Lock Switch 4. Using an ohmmeter, test switch resistance between Pins 2 and 3. 5. Depress switch to UNLOCK position. 6. Test resistance between Pins 2 and 3. 7. Test resistance between pins 2 and 3 while switch is in its normal unactuated mode. 8. If resistance values are not within the parameters shown replace the door lock switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 9508 Power Door Lock Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove door trim panel. 3. Disconnect wire connector from back of door lock switch. 4. Remove two screws to door lock switch. 5. Remove switch from vehicle. INSTALLATION 1. Install the switch into the vehicle. 2. Install the two screws to door lock switch. 3. Connect wire connector to back of door lock switch. 4. Install door trim panel. 5. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock > System Information > Locations Trunk / Liftgate Lock: Locations Liftgate And Sliding Door Modules Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock > System Information > Locations > Page 9512 Left Rear Body Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock > System Information > Locations > Page 9513 Liftgate Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock > System Information > Locations > Page 9514 Trunk / Liftgate Lock: Diagrams C315 (Power Liftgate) C315 (Power Liftgate) Left Liftgate Flood Lamp (Export) Liftgate Cinch/Release Motor (Power Liftgate) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock > System Information > Locations > Page 9515 Power Liftgate Module C1 Power Liftgate Module C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair LOCK CYLINDER REMOVAL 1. Remove the liftgate trim panel. 2. Disconnect the electrical connector. 3. Disconnect the latch rod. 4. Rotate plastic lock cylinder nut one quarter turn and remove nut and spring washer. 5. Remove the lock cylinder from the liftgate. INSTALLATION 1. Install lock cylinder into liftgate. 2. Install the plastic lock cylinder lock nut, spring washer and rotate one quarter turn. 3. Connect the electrical connector. 4. Connect the latch rod. 5. Install the trim panel. 6. Verify lock cylinder operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Mirror Relay > Component Information > Locations Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9527 Memory Positioning Module: Description and Operation Vehicles equipped with the memory seat/mirror option, utilize a memory module located under the drivers front seat. This module is basically wired in-line between the power seat switch and the power seat track/adjuster motors, or in-line between the power mirror switch and the power side view mirror(s) motor(s). The Memory Seat/Mirror Module (MSMM) contains a central processing unit that communicates with other modules on the Programmable Communications Interface (PCI) data bus network. The MSMM receives hard wired inputs from the driver power seat switch and the potentiometers on each of the driver side power seat track motors, or from the power mirror switch and the potentiometers on the side view mirror. The MSMM receives messages over the PCI data bus from the Body Control Module (BCM) (memory switch status), the Powertrain Control Module (PCM) (vehicle speed status). The MSMM will prevent the seat memory recall function from being initiated if the driver side seat belt is buckled, if the transmission gear selector lever is not in the Park or Neutral positions, or if the vehicle is moving. For diagnosis of the MSMM or the PCI data bus, a DRB III(R) scan tool and the proper Diagnostic Procedures Information are recommended. The MSMM cannot be repaired and, if faulty or damaged, it must be replaced. When memory system operation is requested (depressing of the memory switch), a resistor multiplexed signal is sent from the memory switch to the Body Control Module (BCM). The BCM will then send the appropriate signals out to the Memory Seat/ Mirror Module (MSMM), the MSMM then applies the voltage supply to the power seat track or side-view mirror if the proper requirements are met. The vehicle speed must equal zero and the transmission must be in park or neutral in order for the memory system to function. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9528 Memory Positioning Module: Testing and Inspection Any diagnosis of the Memory Seat/Mirror system should begin with the use of the DRB III(R) diagnostic tool. Inspect the related wiring harness connectors for broken, bent, pushed out, or corroded terminals. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9529 Memory Positioning Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side front bucket seat retaining nuts from under the vehicle. 3. Lift the drivers seat up and out of the mounting holes in the floor pan and lay the seat rearward to access the module located under the seat. 4. Disconnect the memory seat/mirror module electrical connectors. Depress the retaining tab and pull straight apart. 5. Remove the module retaining bolts and remove the module from the bracket. INSTALLATION 1. Position and install the module retaining bolts. 2. Connect the memory seat/mirror module electrical connectors. 3. Position the drivers seat in the mounting holes in the floor pan. 4. Install the driver side front bucket seat retaining nuts from under the vehicle. 5. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Driver Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 9533 Memory Set Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 9534 Seat Memory Switch: Description and Operation Memory Switch Location Vehicles equipped with the memory system have a memory switch mounted to the driver side front door trim panel. This switch is used to set and recall all of the memory system settings for up to two drivers. The memory switch is a resistor multiplexed unit that is hard wired to the Body Control Module (BCM). The BCM sends out the memory system set and recall requests to the other electronic modules over the Programmable Communications Interface (PCI) data bus. The memory switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The memory switch has three momentary switch buttons labeled Set, 1 and 2. When the memory set switch is depressed, a resistance value is sent to the Body Control Module (BCM) via hard wired connections. When the memory system is in "set" mode a chime will be generated by the BCM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 9535 Seat Memory Switch: Testing and Inspection MEMORY SWITCH Memory Switch Test Table 1. Remove the memory switch from the drivers door panel. 2. Using an ohmmeter, check the continuity of the memory select switch MUX circuit between the C2 wire harness connector for the Body Control Module (BCM) and the wire harness connector for the memory switch. There should be continuity. If OK, go to Step 3. If not OK, repair the open or shorted MUX circuit as required. 3. Using an ohmmeter, check the continuity of the memory select switch return circuit between the C2 wire harness connector for the BCM and the wire harness connector for the memory switch. There should be continuity. If OK, go to Step 4. If not OK, repair the open or shorted return circuit as required. 4. Using an ohmmeter, test the resistances of the memory switch. If OK, refer to Body and Frame / Seats / Testing and Inspection. If not OK, replace the memory switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 9536 Seat Memory Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door trim panel switch bezel from the driver side front door. Using a thin flat-bladed pry tool, gently pry the switch bezel away from the drivers door trim panel. 3. Disconnect the memory switch wire harness connector from the memory switch. 4. Remove the two screws that secure the memory switch to the back of the driver side front door trim panel switch bezel. 5. Remove the memory switch. INSTALLATION 1. Position the memory switch and install and tighten the two screws that secure the memory switch to the back of the driver side front door trim panel switch bezel. Tighten the screws to 2.2 Nm (20 in. lbs.). 2. Reconnect the memory switch wire harness connector to the memory switch. 3. Install the trim panel switch bezel onto the driver side front door. 4. Reconnect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Control Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Relay > Component Information > Diagrams Passenger Folding Mirror Relay (Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Right Side Instrument Panel Lower RHD Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9546 Power Mirror Switch: Diagrams Power Folding Mirror Switch (Export) Power Mirror Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9547 Power Mirror Switch: Description and Operation POWER FOLDAWAY MIRROR SWITCH-EXPORT Power Foldway Mirror Switch These vehicles may be equipped with Power Fold-away Mirrors. This feature allows both the driver and passenger side view mirrors to fold inward (retract) on demand. The vehicle has an additional switch located on the steering column that controls the folding function of the mirror assembly. The fold-away side view mirror is attached to the vehicle's door in the same manner as mirrors without the fold-away option. The fold-away mirrors unique option is the internal motor which allows the mirrors to fold inward on demand. The fold-away mirror motor is not serviceable separately and if a motor is found to be faulty the entire side view mirror must be replaced. When the mirror retract switch is depressed, both of the side view mirrors will fold inward, Thus making the overall width of the vehicle the smallest possible. This can be helpful were parking space is a absolute minimum. When the driver's door is opened, only the driver's door mirror will unfold. If the passenger door is opened, both mirrors will unfold. The power fold away mirror system consists of the following components: mirror switch, side view mirror, relay, wires and fuse. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 9548 Power Mirror Switch: Testing and Inspection REMOTE SWITCH Mirror Switch Test Part 1 Mirror Switch Test Part 2 1. Remove power mirror switch. 2. Disconnect wiring harness at switch connector. Mirror Switch 3. Using a ohmmeter, test for continuity between the terminals of the switch. 4. If results shown in the table are not obtained, replace the switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Power Foldaway Mirror Switch- Export Power Mirror Switch: Service and Repair Power Foldaway Mirror Switch- Export REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the upper and lower steering column shroud. 3. Disconnect electrical harness connector. Power Folding Mirror Switch 4. Remove switch from steering column shroud. INSTALLATION 1. Install switch to steering column shroud. 2. Connect wire harness connector. 3. Install the upper and lower steering column shroud. 4. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Power Foldaway Mirror Switch- Export > Page 9551 Power Mirror Switch: Service and Repair Remote Switch REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel lower cover. 3. From behind headlamp switch assembly, depress retaining tabs and push switch from instrument panel. 4. Disconnect wire connector from power mirror switch. 5. Disengage lock tabs above and below the mirror switch. 6. Remove power mirror switch from headlamp switch bezel. INSTALLATION 1. Install power mirror switch to the headlamp switch bezel. 2. Connect wire connector to the power mirror switch. 3. Insert headlamp switch assembly into instrument panel. 4. Install instrument panel lower cover. 5. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes Paint: Application and ID Paint Codes Exterior Colors Interior Colors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Paint Codes > Page 9557 Paint: Application and ID Paint Code Location Body Code Plate The Body Code Plate is located in the engine compartment on the radiator closure panel crossmember. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Page 9558 Paint: Description and Operation BASE COAT / CLEARCOAT FINISH DESCRIPTION On most vehicles a two-part paint application (basecoat/clearcoat) is used. Color paint that is applied to primer is called basecoat. The clearcoat protects the basecoat from ultraviolet light and provides a durable high-gloss finish. CAUTION: Do not use abrasive chemicals or compounds on painted surfaces. Damage to finish can result. Do not use harsh alkaline based cleaning solvents on painted surfaces. Damage to finish or color can result. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up Paint: Service and Repair Paint Touch-Up PAINTED TOUCH - UP DESCRIPTION When a painted metal surface has been scratched or chipped, it should be touched up as soon as possible to avoid corrosion. For best results, use Mopar(R) Scratch Filler/Primer, Touch Up Paints and Clear Top Coat. Refer to Information Labels. WARNING: Use an OSHA approved respirator and safety glasses when spraying paint or solvents in a confined area. Personal injury can result. TOUCH UP PROCEDURE 1. Scrape loose paint and corrosion from inside scratch or chip. 2. Clean affected area with Mopar(R) Tar/Road Oil Remover, and allow to dry. 3. Fill the inside of the scratch or chip with a coat of filler/primer. Do not overlap primer onto good surface finish. The applicator brush should be wet enough to puddle-fill the scratch or chip without running. Do not stroke brush applicator on body surface. Allow the filler/primer to dry hard. 4. Cover the filler/primer with color touch up paint. Do not overlap touch up color onto the original color coat around the scratch or chip. Butt the new color to the original color, if possible. Do not stroke applicator brush on body surface. Allow touch up paint to dry hard. 5. On vehicles without clearcoat, the touch up color can be lightly finesse sanded (1500 grit) and polished with rubbing compound. 6. On vehicles with clearcoat, apply clear top coat to touch up paint with the same technique as described in Step 4. Allow clear top coat to dry hard. If desired, Step 5 can be performed on clear top coat. WARNING: AVOID PROLONGED SKIN CONTACT WITH PETROLEUM OR ALCOHOL - BASED CLEANING SOLVENTS. PERSONAL INJURY CAN RESULT. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up > Page 9561 Paint: Service and Repair Finesse Sanding, Buffing, And Polishing - Description FINESSE SANDING / BUFFING & POLISHING DESCRIPTION Minor acid etching, orange peel, or smudging in clearcoat or single-stage finishes can be reduced with light finesse sanding, hand buffing, and polishing. If the finish has been finesse sanded in the past, it cannot be repeated. Finesse sanding operation should be performed by a trained automotive paint technician. CAUTION: Do not remove clearcoat finish, if equipped. Basecoat paint must retain clearcoat for durability. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair Radiator Support: Service and Repair UPPER RADIATOR CROSSMEMBER REMOVAL 1. Release hood latch and open hood. 2. Remove radiator sight shield. 3. Remove engine air inlet resonator. 4. Unclip hood cable from upper radiator crossmember. 5. Remove bolts attaching hood latch to crossmember and position latch out of the way. 6. Remove hood prop rod. 7. Remove screw attaching coolant recovery bottle to crossmember. 8. Remove bolts attaching radiator isolators to crossmember. Fig. 16 9. Remove bolts attaching ends of crossmember to radiator closure panel (Fig. 16). 10. Lift crossmember upward and away from radiator closure panel. 11. Remove crossmember from vehicle. INSTALLATION 1. Place radiator closure panel crossmember in position on vehicle. 2. Insert ends of crossmember between layered metal sections of radiator closure panel at each side of radiator. 3. Align with paint breaks around bolt heads. 4. Install bolts attaching ends of crossmember to radiator closure panel (Fig. 16). Tighten bolts to 19 N.m (14 ft.lbs.) torque. 5. Install bolts attaching radiator isolators to crossmember. 6. Install screw attaching coolant recovery bottle to crossmember. 7. Install bolt attaching air cleaner housing to crossmember. 8. Install engine air inlet resonator. 9. Install hood prop rod. 10. Align hood latch by placing latch over net pierce tabs. If alignment is required, flatten tabs. 11. Install bolts attaching hood latch to crossmember and clip cable. Tighten bolts to 13.5 N.m (10 ft.lbs.) torque. 12. Install radiator sight shield. 13. Verify hood latch operation and hood alignment. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Heated Mirror Relay > Component Information > Locations Integrated Power Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations > Page 9573 Keyless Entry Module: Connector Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations > Page 9574 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations > Page 9575 Steering Column Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations > Page 9576 Center Instrument Panel Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Component Locations > Page 9577 Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 9578 Sentry Key Remote Entry Module (Skreem) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 9579 Keyless Entry Module: Description and Operation The Sentry Key Remote Entry Module (SKREEM) performs the functions of the Sentry Key Immobilizer Module (SKIM), Remote Keyless Entry (RKE) Module, and the Tire Pressure Monitoring (TPM) System (previously part of the Electronic Vehicle Information Center (EVIC). The SKREEM is located in the same location as the SKIM was and is mounted the same way. It looks identical, but has added capabilities. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 9580 Keyless Entry Module: Testing and Inspection For proper diagnosis and testing of the Sentry Key Remote Entry Module (SKREEM), use a DRBIII (R) and refer to the proper Body Diagnostic Procedures information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 9581 Keyless Entry Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the Steering Column Opening Cover. 3. Remove the steering column upper and lower shrouds. 4. Disengage the steering column wire harness from the Sentry Key Remote Entry Module (SKREEM). 5. Remove the one screws securing the SKREEM to the steering column. 6. Rotate the SKREEM upwards and then to the side away from the steering column to slide the SKREEM antenna ring from around the ignition switch lock cylinder housing. 7. Remove the SKREEM from the vehicle. INSTALLATION 1. Slip the Sentry Key Remote Entry Module (SKREEM) antenna ring around the ignition switch lock cylinder housing. Rotate the SKREEM downwards and then towards the steering column. 2. Install the one screws securing the SKREEM to the steering column. 3. Connect the steering column wire harness to the SKREEM. 4. Install the steering column upper and lower shrouds. 5. Install the Steering Column Opening Cover. 6. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 9585 Memory Positioning Module: Description and Operation Vehicles equipped with the memory seat/mirror option, utilize a memory module located under the drivers front seat. This module is basically wired in-line between the power seat switch and the power seat track/adjuster motors, or in-line between the power mirror switch and the power side view mirror(s) motor(s). The Memory Seat/Mirror Module (MSMM) contains a central processing unit that communicates with other modules on the Programmable Communications Interface (PCI) data bus network. The MSMM receives hard wired inputs from the driver power seat switch and the potentiometers on each of the driver side power seat track motors, or from the power mirror switch and the potentiometers on the side view mirror. The MSMM receives messages over the PCI data bus from the Body Control Module (BCM) (memory switch status), the Powertrain Control Module (PCM) (vehicle speed status). The MSMM will prevent the seat memory recall function from being initiated if the driver side seat belt is buckled, if the transmission gear selector lever is not in the Park or Neutral positions, or if the vehicle is moving. For diagnosis of the MSMM or the PCI data bus, a DRB III(R) scan tool and the proper Diagnostic Procedures Information are recommended. The MSMM cannot be repaired and, if faulty or damaged, it must be replaced. When memory system operation is requested (depressing of the memory switch), a resistor multiplexed signal is sent from the memory switch to the Body Control Module (BCM). The BCM will then send the appropriate signals out to the Memory Seat/ Mirror Module (MSMM), the MSMM then applies the voltage supply to the power seat track or side-view mirror if the proper requirements are met. The vehicle speed must equal zero and the transmission must be in park or neutral in order for the memory system to function. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 9586 Memory Positioning Module: Testing and Inspection Any diagnosis of the Memory Seat/Mirror system should begin with the use of the DRB III(R) diagnostic tool. Inspect the related wiring harness connectors for broken, bent, pushed out, or corroded terminals. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations > Page 9587 Memory Positioning Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side front bucket seat retaining nuts from under the vehicle. 3. Lift the drivers seat up and out of the mounting holes in the floor pan and lay the seat rearward to access the module located under the seat. 4. Disconnect the memory seat/mirror module electrical connectors. Depress the retaining tab and pull straight apart. 5. Remove the module retaining bolts and remove the module from the bracket. INSTALLATION 1. Position and install the module retaining bolts. 2. Connect the memory seat/mirror module electrical connectors. 3. Position the drivers seat in the mounting holes in the floor pan. 4. Install the driver side front bucket seat retaining nuts from under the vehicle. 5. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Locations > Page 9591 Pedal Positioning Module: Diagrams Memory Seat/Mirror/Adjustable Pedals Module C1 Memory Seat/Mirror/Adjustable Pedals Module C2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Pedal Positioning Module > Component Information > Locations > Page 9592 Memory Seat/Mirror/Adjustable Pedals Module C3 Memory Seat/Mirror/Adjustable Pedals Module C4 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Pedal Positioning Relay > Component Information > Locations Left Side Engine Compartment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Pedal Positioning Relay > Component Information > Locations > Page 9596 Adjustable Pedals Relay (Except Export/Except Memory) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Control Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Mirror Relay > Component Information > Diagrams Passenger Folding Mirror Relay (Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation Power Seat Control Module: Description and Operation Vehicles equipped with heated seats utilize two heated seat modules. The heated seat modules are located under the front seats, where they are secured to the seat cushion pans. Each heated seat module has three connector receptacles that allow the modules to be connected to all of the required inputs and outputs through the seat wire harness. The heated seat modules are an electronic microprocessor controlled device designed and programmed to use inputs from the ignition switch, heated seat switch and the heated seat sensor to operate and control the heated seat elements in the front seat. The heated seat module operates on fused battery current received from the Integrated Power Module (IPM). The module is grounded at all times through the seat wire harness. Inputs to the module include a resistor multiplexed heated seat switch request circuit for the heated seat switch and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements. When a heated seat switch request signal is received by the heated seat module and the enable input is high, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is approximately 36° C (95° F), and the High heat set point is approximately 40° C (104° F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the N-FET which de-energizes the heated seat elements. The heated seat module will continue to cycle the N-FET as needed to maintain the selected temperature set point. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Page 9606 Power Seat Control Module: Testing and Inspection If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. If the heated seat switch checks OK, proceed as follows. 1. Check the heated seat element. 2. Check the heated seat sensor. 3. Using a voltmeter, back probe the appropriate heated seat module connector, do not disconnect. Check for battery voltage at the appropriate pin cavities. If OK go to Step 4. If not OK, repair the open or shorted voltage supply circuit as required. 4. Using a ohmmeter, back probe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK replace the heated seat module. If Not OK, repair the open or shorted ground circuit as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module > Component Information > Description and Operation > Page 9607 Power Seat Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the appropriate front seat from the vehicle. 3. Unsnap the module from the seat cushion pan. 4. Disconnect the module wire harness connectors. INSTALLATION 1. Connect the module wire harness connectors. 2. Snap the module on the seat cushion pan. 3. Install the appropriate front seat in the vehicle. 4. Connect and isolate the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Sliding Door Module > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Sliding Door Module > Component Information > Locations > Component Locations > Page 9612 Power Sliding Door Module: Connector Locations Right Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Sliding Door Module > Component Information > Locations > Component Locations > Page 9613 Liftgate And Sliding Door Modules Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Sliding Door Module > Component Information > Locations > Page 9614 Power Sliding Door Module: Diagrams Left Sliding Door Control Module C1 (Power Sliding Door) Left Sliding Door Control Module C2 (Power Sliding Door) Right Sliding Door Control Module C1 (power Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Sliding Door Module > Component Information > Locations > Page 9615 Right Sliding Door Control Module C2 (power Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Sliding Door Module > Component Information > Locations > Page 9616 Power Sliding Door Module: Description and Operation Power Side Door Components Vehicles equipped with a power sliding door system utilize a sliding door control module. The sliding door control module is located behind the sliding door trim panel in the center of the door, just above the sliding door motor. This module controls the operation of the door through the Programmable Communication Interface (PCI) data bus circuit and the Body Control Module (BCM). The sliding door control module contains software technology which enables it to detect resistance to door travel and to reverse door travel in order to avoid damage to the door or to avoid possible personal injury if the obstruction is a person. This feature functions in both the opening and closing cycles. If the power sliding door system develops any problems the control module will store and recall Diagnostic Trouble Codes (DTC). The use of a diagnostic scan tool, such as the DRB III(R) is required to read and troubleshoot these trouble codes. The sliding door control module can be reflashed if necessary. Refer to the latest Technical Service Bulletin (TSB) Information for any updates. The power door control module is a replaceable component and cannot be repaired, if found to be faulty it must be replaced. The power sliding door control module serves as the main computer for the power sliding door system. All power door functions are processed through the power sliding door control module and/or the vehicles Body Control Module (BCM). At the start of a power open command, a signal is sent to the BCM and then to the power sliding door control module via the Programmable Communication Interface (PCI) data bus circuit. This signal, generated by any of the power door command switches, tells the power sliding door control module to activate a power latch release, engage the clutch assembly and drive the door into the full open position. If an obstacle is felt during this power open cycle, the module will reverse direction and close the door. This process is also enabled during a power close cycle. This process will repeat three times, and if a fourth obstacle is detected, the door will go into full manual mode. Once the full open position is obtained, a hold open latch assembly mounted full open switch tells the power sliding door control module that the door has reached the full open position. If the power sliding door system develops any problems the power sliding door control module will store and recall Diagnostic Trouble Codes (DTC). The use of a diagnostic scan tool, such as the DRB III(R) is required to read and troubleshoot these trouble codes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Sliding Door Module > Component Information > Locations > Page 9617 Power Sliding Door Module: Testing and Inspection Any diagnosis of the power sliding door system should begin with the use of the DRB III(R) diagnostic tool. Inspect the related wiring harness connectors for broken, bent, pushed out, or corroded terminals. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Sliding Door Module > Component Information > Locations > Page 9618 Power Sliding Door Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the appropriate door trim panel from the vehicle. 3. Remove the weather shield. 4. Disconnect the power door control module electrical connectors. Slide the red locking tab out (away from module) and depress connector retaining tab, while pulling straight apart. Power Side Door Components 5. Remove the control module retaining screw. 6. Remove the module from the vehicle. INSTALLATION 1. Position the sliding door control module and install the retaining screw. 2. Connect the electrical connectors. Slide the locking tab into the locked position. 3. Install the weather shield. 4. Install the appropriate door trim panel on the vehicle. 5. Connect the battery negative cable. 6. Using an appropriate scan tool, check and erase any power door control module diagnostic trouble codes. 7. Verify power door system operation. Cycle the power door through one complete open and close cycle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Trunk / Liftgate Control Module: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly Power Trunk / Liftgate Control Module: Customer Interest Body - Power Liftgate Does Not Open/Close Properly NUMBER: 08-045-06 GROUP: Electrical DATE: October 17, 2006 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. WHILE THE FILES ARE CURRENTLY AVAILABLE FROM THE INTERNET FOR ALL MARKETS, FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE DRBIII(R) FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL ALSO BE AVAILABLE ON ITIL/ISIS DVD 4th QUARTER, 2006. SUBJECT: Flash: Power Liftgate May Not Open Or Close The First Time That The Power Liftgate Button Is Depressed OVERVIEW: This bulletin involves selectively erasing and reprogramming the Power Liftgate Module with new software. MODELS: 2002 - 2007 (RS/RG) Town & Country/Caravan/Voyager NOTE: This bulletin applies to vehicles equipped with a Power Liftgate (sales code JRC) built on or before October 13, 2006 (MDH 1013XX). SYMPTOM/CONDITION: The vehicle operator may describe that the Power Liftgate may not open or close the first time that the Power Liftgate button is depressed. If the button is pressed repeatedly, the liftgate will open or close properly. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII® connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE FOR DOMESTIC VEHICLES DOWNLOADING FLASH FILES FROM DealerCONNECT> Tech TOOLS: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Trunk / Liftgate Control Module: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly > Page 9627 NOTE Remove any unnecessary PCMCIA cards prior to starting a DRBIII(R) flash. 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the Power Liftgate Module currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2007 Diagnostics". c. "All (Except Below)". d. "Body Interior". e. "Doors, Gates & Comfort". f. "Power Lift Module". g. "Module Display". h. Record the "Power Liftgate Module part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "Power Liftgate Module part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the '~Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to next step. NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Customer Interest for Power Trunk / Liftgate Control Module: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly > Page 9628 Due to the Power Liftgate Module programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Trunk / Liftgate Control Module: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly Power Trunk / Liftgate Control Module: All Technical Service Bulletins Body - Power Liftgate Does Not Open/Close Properly NUMBER: 08-045-06 GROUP: Electrical DATE: October 17, 2006 THE DRBIII(R) FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON DealerCONNECT. WHILE THE FILES ARE CURRENTLY AVAILABLE FROM THE INTERNET FOR ALL MARKETS, FOR MARKETS OUTSIDE OF THE UNITED STATES AND CANADA, THE DRBIII(R) FLASH FILES AND REPROGRAMMING INSTRUCTIONS WILL ALSO BE AVAILABLE ON ITIL/ISIS DVD 4th QUARTER, 2006. SUBJECT: Flash: Power Liftgate May Not Open Or Close The First Time That The Power Liftgate Button Is Depressed OVERVIEW: This bulletin involves selectively erasing and reprogramming the Power Liftgate Module with new software. MODELS: 2002 - 2007 (RS/RG) Town & Country/Caravan/Voyager NOTE: This bulletin applies to vehicles equipped with a Power Liftgate (sales code JRC) built on or before October 13, 2006 (MDH 1013XX). SYMPTOM/CONDITION: The vehicle operator may describe that the Power Liftgate may not open or close the first time that the Power Liftgate button is depressed. If the button is pressed repeatedly, the liftgate will open or close properly. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: NOTE: An updated J1962 cable has been released. This cable has a red colored connector at the DRBIII® connection. Use this cable whenever a flash is being performed. REPAIR PROCEDURE FOR DOMESTIC VEHICLES DOWNLOADING FLASH FILES FROM DealerCONNECT> Tech TOOLS: NOTE: Whenever a module is reprogrammed, the software in the DRBIII(R); must be programmed with the latest revision level available. NOTE: If this flash process is interrupted/aborted, the flash process should be restarted and then follow the directions on the DRBIII(R). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Trunk / Liftgate Control Module: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly > Page 9634 NOTE Remove any unnecessary PCMCIA cards prior to starting a DRBIII(R) flash. 1. Before beginning the flash procedure, remove any old flash files from the DRBIII(R) memory. To clear the memory from the MAIN MENU: a. Simultaneously press the "MORE" and "YES" keys. b. A screen will appear requesting a "COLD BOOT". c. Follow the on screen instructions by selecting the "F4" key. d. When the DRBIII(R) reboots to the MAIN MENU, proceed to Step # 2. 2. With the ignition switch in the "RUN" position, determine the original part number of the Power Liftgate Module currently in the vehicle. Using the DRBIII(R) select: a. "DRBIII(R) Standalone". b. "1998 - 2007 Diagnostics". c. "All (Except Below)". d. "Body Interior". e. "Doors, Gates & Comfort". f. "Power Lift Module". g. "Module Display". h. Record the "Power Liftgate Module part # " on the repair order for later reference. 3. Connect the DRBIII(R) to TechCONNECT. Open TechTOOLS and verify that the "DRBIII(R) Status: Connected" message is in the upper right corner of the TechTOOLS screen. 4. Enter the "Power Liftgate Module part # " recorded in Step # 2 in the "Parts Criteria" area and select "Show Updates". TechTOOLS will populate the appropriate flash file. 5. Select the flash file. 6. Select the "DRBIII" radio button which is next to the "Download/Update" button. 7. Select the '~Download/Update" button. 8. Monitor the "Flash Download/Update Progress" window on the TechCONNECT and follow the instructions on TechCONNECT. When the flash process is complete, proceed to Step # 9. 9. Disconnect the DRBIII(R) from TechCONNECT. 10. Open the hood and install a battery charger. Using a voltmeter, verify that the charging rate provides 13.2 - 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. NOTE: Do not allow the charging voltage to climb above 13.5 volts during the flash process. 11. Connect the DRBIII(R) to the vehicle. 12. Download the flash file from the DRBIII(R) to the vehicle. Using the DRBIII(R) select: a. "Vehicle Flash". b. Follow the directions on the DRBIII(R) screen. When the flash process is complete, proceed to next step. NOTE: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Trunk / Liftgate Control Module: > 08-045-06 > Oct > 06 > Body - Power Liftgate Does Not Open/Close Properly > Page 9635 Due to the Power Liftgate Module programming procedure, a DTC may be set in other modules within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. Check all modules using "Module Scan", record the DTC's, and erase these DTC's prior to returning the vehicle to the customer. Erase any DTC's in the PCM only after all other modules have had their DTC's erased. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 9636 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 9637 Power Trunk / Liftgate Control Module: Description and Operation Power Liftgate Control Module Vehicles equipped with a power liftgate (PLG) utilize a PLG control module. This module is located on the vehicles left side D-pillar just below the motor assembly and contains a microprocessor, which is used to communicate to the vehicles body control module. The PLG control module receives and monitors logic inputs from all the PLG system switches except for the outside handle switch. This module also contains the software technology to detect liftgate obstructions and stop and/or reverse the door accordingly. The power liftgate control module contains the electronic circuitry and software used to control the sequence of events for the power liftgate system. This module communicates on the Programmable Communications Interface (PCI) bus circuit with the vehicles Body Control Module (BCM) to monitor many different inputs and outputs such as door lock status, transmission gear selector position and vehicle speed. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 9638 Power Trunk / Liftgate Control Module: Testing and Inspection Any diagnosis of the Power Liftgate system should begin with the use of the DRB III(R) diagnostic tool. Inspect the related wiring harness connectors for broken, bent, pushed out, or corroded terminals. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Technical Service Bulletins > Page 9639 Power Trunk / Liftgate Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left D-pillar trim panel from the vehicle. 3. Disconnect the wire harness connections from the power liftgate motor assembly. Power Liftgate Control Module 4. Remove the screw holding the power liftgate control module to the D-pillar. 5. Remove the power liftgate control module from the vehicle. INSTALLATION 1. Install the Power Liftgate (PLG) control module on the D-pillar and install retaining screw. 2. Connect the wire harness connections to the PLG control module. Be certain to slide connector locks to the locked position. 3. Install the D-pillar trim panel on the vehicle. 4. Connect the battery negative cable. 5. Using an appropriate scan tool, check and erase any PLG control module diagnostic trouble codes. 6. Verify PLG system operation. Cycle the PLG through one complete open and close cycle, this will allow the PLG control module to relearn its cycle with the new components. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams Seat Heater Control Module: Diagrams Driver Heated Seat Module C1 Driver Heated Seat Module C2 Driver Heated Seat Module C3 Passenger Heated Seat Module (Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Diagrams > Page 9643 Passenger Heated Seat Module C1 (Export) Passenger Heated Seat Module C2 (Export) Passenger Heated Seat Module C3 (Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof Module (Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Luggage Rack Riser Luggage Rack: Service and Repair Luggage Rack Riser LUGGAGE RACK RISER REMOVAL Fig. 18 1. Remove two fasteners from the front riser. Gently pull up on the luggage rack side rail and detach the riser snap to remove riser from the rail (Fig. 18). 2. Repeat for the opposite side, if necessary. Fig. 19 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Luggage Rack Riser > Page 9652 3. Remove front riser(s) from vehicle (Fig. 19). INSTALLATION 1. Place front riser into position on luggage rack side rail. 2. Install two fasteners into the riser. 3. Repeat for the opposite side, if necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Service and Repair > Luggage Rack Riser > Page 9653 Luggage Rack: Service and Repair Luggage Rack Crossbar LUGGAGE RACK CROSSBAR REMOVAL 1. Remove luggage rack front risers. Fig. 20 2. Depress stanchion levers down until they click into the unlock position. (Fig. 20). Work from side to side sliding the crossbar assembly forward moving a little at a time to ensure it remains perpendicular to the side rails. 3. Remove crossbar from vehicle. INSTALLATION NOTE: The crossbar assemblies are designed to be installed in only one way. Check top and bottom surfaces of the crossbar for the word FRONT and directional arrows. The directional arrows must point toward the front of the vehicle. 1. Place crossbar in position on vehicle. 2. Work from side to side sliding the crossbar assembly back a little at a time to ensure it remains perpendicular to the side rails. 3. Position first crossbar assembly crossbar at the second most rearward locator holes. Press the top of the stanchion lever to lock it into position. 4. Position the second crossbar assembly in the second hole from the front. Lock into place. 5. Place luggage rack riser into position. 6. Install two fasteners into riser. Tighten fasteners to 4 mm (35 in.lbs.) torque. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Motor/Module-Sunroof Sunroof / Moonroof Motor: Testing and Inspection Motor/Module-Sunroof For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. If the power top is completely inoperative perform the following diagnostic steps. 1. Check the B+ 40 amp fuse in the Integrated Power Module (IPM). If OK, goto Step 2. If not OK, repair the shorted circuit or component as required and replace the inoperative fuse. 2. Check the Accessory delay 20 amp fuse in the IPM. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the inoperative fuse. 3. Partially remove the headliner to access the sunroof motor/module. 4. Disconnect the motor/module electrical connector. Using a voltmeter check for Battery voltage at the B+ terminal of the harness connector. If OK, go to Step 5. If not OK, repair the B+ circuit as necessary. 5. With the ignition switch in the "RUN" position check for Battery voltage at the Accessory Relay Output terminal of the harness connector. If OK , go to Step 6. If not OK repair the Accessory Relay Output circuit as necessary. 6. Using an ohmmeter test for continuity between the harness connector ground circuit and a known good ground. Continuity should be present. If OK go to Step 7. If not OK, repair the open ground circuit as necessary. 7. Turn the ignition switch to the "OFF" position. Reconnect the motor/module electrical connector. With the ignition switch in the "RUN" position check for battery voltage on the "VENT", "CLOSE" and "OPEN" circuits at the back side of the motor/module connector. If OK, go to Step 8. If not OK replace the motor/module assembly. 8. Turn the ignition switch to the "OFF" position. Disconnect the motor/module and sunroof switch electrical connectors. Using an ohmmeter check for continuity on the "VENT", "CLOSE" and "OPEN" circuits between the motor/module and sunroof switch. Continuity should be present. If OK, for diagnosis of the sunroof switch. If not OK, repair the control circuits as necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Motor/Module-Sunroof > Page 9659 Sunroof / Moonroof Motor: Testing and Inspection Sunroof Motor/Module Calibration CAUTION: There is no adjustment available for a normally operating sunroof. this procedure is used to set sunroof motor/ module to sunroof assembly timing. Sunroof Guide Lock Position 1. Manually push the sunroof guide assembly to the full forward position until it is locked into position. This is verified by attempting to push the guide assembly rearward. NOTE: The guide rail will be raised above the U-frame assembly when in the lock position. 2. Remove the sunroof glass. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Motor/Module-Sunroof > Page 9660 Sunroof Guide Guide Pivot 3. Manually move the guide pivot inside the guide rail cam slot until it is centered between the etched timing marks on both rails. Sunroof Motor/Module 4. Verify that the white marking is visible in the new motor/module window. If the mark is not visible, connect a power source to the motor/module and cycle the switch until the motor/module is in the closed position (white mark in window). 5. Install the sunroof motor/module and verify proper sunroof operation. 6. Install the sunroof glass, leaving the retaining bolts loose. 7. Install the sunroof assembly into the vehicle. 8. Flush the sunroof glass into the vehicle roof opening and check sunroof glass alignment. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Testing and Inspection > Page 9661 Sunroof / Moonroof Motor: Service and Repair REMOVAL Sunroof Motor/Module 1. Remove the sunroof assembly, 2. Remove the sunroof motor/module retaining bolts and remove the motor/module from the vehicle. INSTALLATION CAUTION: The sunroof motor/module must be timed with the sunroof assembly. Failure to do so will result in improper sunroof operation and possible leakage or damage to the assembly. 1. Assure proper sunroof motor/module timing before installation. 2. Position the sunroof motor/module to the sunroof assembly and install the retaining bolts. Tighten sunroof motor/module retaining bolts to 4.2Nm (40 lbs.in.). 3. Connect the timed sunroof assembly to a power source and assure proper operation before installing the sunroof assembly into the vehicle. 4. Install the sunroof assembly in the vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams Sunroof Module (Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 9665 Sunroof / Moonroof Switch: Description and Operation Power Sunroof Switch The power sunroof switch is a combination pushbutton and rocker switch mounted in the overhead console. The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/ module assembly. The sunroof switch performs the following functions: - Power sunroof open - Power sunroof closed - Power sunroof vent The sunroof is electrically operated from two switches located on the windshield header, rearward of the map lamp. The "VENT" switch is a push button type switch and opens the sunroof to the vent position only. The other switch "OPEN/CLOSED" is a rocker type switch for opening and closing the sunroof. Pressing and releasing the open button once, the sunroof will express open and the wind deflector will raise. If the button is pressed a second time the sunroof will stop in that position. Pressing and holding the close button will close the sunroof. If the close button is released the sunroof will stop in that position. The switch is grounded at one terminal and receives a 12 volt signal from the sunroof motor/module on the remaining three terminals. The switch pulls down the 12 volt reference voltage from the motor/ module signaling it to perform the desired function. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 9666 Sunroof / Moonroof Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Perform the following test prior to switch replacement. 1. Remove the overhead console. 2. Disconnect the power sunroof switch wire harness connector. 3. With the ignition key in the "RUN" position check for battery voltage on the "OPEN", "CLOSE" and "VENT" circuits of the sunroof switch harness connector. If OK, go to Step 4. If not OK, inspect the wiring harness and connectors between the motor/ module and switch for damage and repair as necessary. 4. With the ignition key in the "OFF" position check for continuity between the ground circuit of the sunroof switch harness connector and a known good ground. Continuity should be present. If OK, go to Step 5. If not OK, inspect the wiring harness and connector and repair the ground circuit as necessary. Sunroof Switch Pinout Power Sunroof Switch Continuity Table 5. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. If OK, inspect the wiring harness and connectors for damage and repair as necessary. If not OK, replace the power sunroof switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 9667 Sunroof / Moonroof Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Overhead Console 2. Separate the overhead console from the head-liner, by carefully pulling down on the front portion, toward the windshield, to release the retaining clips. 3. Release the sunroof switch retaining tab, disconnect the electrical connector and remove the switch from the overhead console. INSTALLATION Overhead Console 1. Position the sunroof switch against the overhead console and push the switch to properly seat in retaining clip. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 9668 2. Install the overhead console assembly. 3. Connect the battery negative cable. 4. Confirm proper sunroof system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof Module (Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Service and Repair > Child Seat Module, Bench Seat Child Seat: Service and Repair Child Seat Module, Bench Seat CHILD SEAT MODULE, BENCH SEAT REMOVAL 1. Close child restraint seat. 2. Remove seat back cover. Fig. 1 3. Remove screws attaching child restraint seat module hinges to seat back frame lower rail (Fig. 1). 4. Return seat back to upright position. Fig. 2 5. Disengage push in fasteners attaching upper bolster to child restraint seat module (Fig. 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Service and Repair > Child Seat Module, Bench Seat > Page 9677 Fig. 3 6. Remove screws attaching top of module to seat back frame upper rail (Fig. 3). Fig. 4 7. Remove child restraint seat module from seat back (Fig. 4). INSTALLATION INSTALLATION 1. Place child restraint seat module in position on seat back (Fig. 4). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Service and Repair > Child Seat Module, Bench Seat > Page 9678 Fig. 5 2. Position seat back hinge interlock lever over the top of the outboard child restraint seat hinge (Fig. 5). 3. Install screws attaching child restraint seat module hinges to seat back frame lower rail (Fig. 1). 4. Install screws attaching top of module to seat back frame upper rail (Fig. 3). Tighten nuts to 7 N.m (62 in.lbs.) torque. 5. Install push in fasteners attaching upper bolster to child restraint seat module (Fig. 2). 6. Return seat back to folded position. 7. Install seat back cover. 8. Check belt for smooth operation and verify interlock operation. Recliner should not operate with child seat deployed. SYNCHRONIZING CABLE ADJUSTMENT NOTE: Bench seats equipped with child restraint seats have an interlock feature that will not allow the seat back to fold forward with the child seat open. If the seat back hinges do not release at the same time the synchronizing cable must be adjusted. 1. Remove seat from vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Service and Repair > Child Seat Module, Bench Seat > Page 9679 Fig. 6 2. Disengage cable from the recline mechanism by pulling the cable end toward the front of the seat (Fig. 6). 3. Pull U-shaped locking tab on self-adjusting mechanism to disengage auto-adjust feature. 4. Reattach self-adjusting mechanism, pulling against spring load to tighten cable. 5. Press locking tab onto the adjusting mechanism to lock into place. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Service and Repair > Child Seat Module, Bench Seat > Page 9680 Child Seat: Service and Repair Quad Child Seat QUAD CHILD SEAT REMOVAL 1. Remove the seat. Fig. 7 2. Remove seat back cover (Fig. 7). Fig. 8 3. Remove fasteners attaching quad child seat to the seat (Fig. 8). 4. Remove quad child seat from the seat. INSTALLATION 1. Place quad child seat in position. 2. Install fasteners and tighten to 13.5 N.m (10 ft.lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Service and Repair > Child Seat Module, Bench Seat > Page 9681 3. Install seat back cover. 4. Install seat in vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Headrest Head Rest: Service and Repair Headrest HEADREST REMOVAL 1. Lift head restraint to top of travel. Fig. 9 2. Depress lock button on side of sleeve at top of seat back (Fig. 9). 3. Pull head restraint from top of seat back. INSTALLATION 1. Place head restraint in position. 2. Depress lock button on side of sleeve at top of seat back. 3. Push heat restraint down into position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Headrest > Page 9686 Head Rest: Service and Repair Headrest Sleeve HEADREST SLEEVE REMOVAL 1. Remove head restraint. 2. Remove back panel. 3. Reach up under back frame back plate. Fig. 10 4. Pinch retainer barbs on end of head restraint sleeve together (Fig. 10). Fig. 11 5. Pull head restraint sleeve upward and out the top of the seat back frame guide tube (Fig. 11). INSTALLATION 1. Insert head restraint sleeve into guide tube at top of trimmed seat back. 2. Push head restraint sleeve downward until retainer clicks into lock position. 3. Install seat back panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Headrest > Page 9687 4. Install head restraint. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Headrest > Page 9688 Head Rest: Service and Repair Headrest Sleeve - Second Row - Stow - N - Go HEADREST SLEEVE - SECOND ROW - STOW - N - GO REMOVAL Fig. 51 1. Remove headrest (Fig. 51). Fig. 52 2. Using a trim tool remove sleeve by prying sleeve away from the seat back frame to unlock it (Fig. 52). 3. Pull headrest sleeve upward and out the top of the seat back frame and remove from seat. INSTALLATION 1. Place headrest sleeve into position and push downward until sleeve locks into position. 2. Install headrest (Fig. 51). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Headrest > Page 9689 Head Rest: Service and Repair Headrest Sleeve - Third Row - Stow - N - Go HEADREST SLEEVE - THIRD ROW - STOW - N - GO REMOVAL Fig. 104 1. Remove headrest (Fig. 104). Fig. 105 2. Using a trim tool remove sleeve by prying sleeve away from the seat back frame to unlock it (Fig. 105) 3. Pull headrest sleeve upward and out the top of the seat back frame and remove from seat. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Headrest > Page 9690 Fig. 106 1. Place headrest sleeve into position and push downward until sleeve locks into position (Fig. 106). 2. Install headrest (Fig. 104). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9695 Memory Positioning Module: Description and Operation Vehicles equipped with the memory seat/mirror option, utilize a memory module located under the drivers front seat. This module is basically wired in-line between the power seat switch and the power seat track/adjuster motors, or in-line between the power mirror switch and the power side view mirror(s) motor(s). The Memory Seat/Mirror Module (MSMM) contains a central processing unit that communicates with other modules on the Programmable Communications Interface (PCI) data bus network. The MSMM receives hard wired inputs from the driver power seat switch and the potentiometers on each of the driver side power seat track motors, or from the power mirror switch and the potentiometers on the side view mirror. The MSMM receives messages over the PCI data bus from the Body Control Module (BCM) (memory switch status), the Powertrain Control Module (PCM) (vehicle speed status). The MSMM will prevent the seat memory recall function from being initiated if the driver side seat belt is buckled, if the transmission gear selector lever is not in the Park or Neutral positions, or if the vehicle is moving. For diagnosis of the MSMM or the PCI data bus, a DRB III(R) scan tool and the proper Diagnostic Procedures Information are recommended. The MSMM cannot be repaired and, if faulty or damaged, it must be replaced. When memory system operation is requested (depressing of the memory switch), a resistor multiplexed signal is sent from the memory switch to the Body Control Module (BCM). The BCM will then send the appropriate signals out to the Memory Seat/ Mirror Module (MSMM), the MSMM then applies the voltage supply to the power seat track or side-view mirror if the proper requirements are met. The vehicle speed must equal zero and the transmission must be in park or neutral in order for the memory system to function. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9696 Memory Positioning Module: Testing and Inspection Any diagnosis of the Memory Seat/Mirror system should begin with the use of the DRB III(R) diagnostic tool. Inspect the related wiring harness connectors for broken, bent, pushed out, or corroded terminals. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations > Page 9697 Memory Positioning Module: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side front bucket seat retaining nuts from under the vehicle. 3. Lift the drivers seat up and out of the mounting holes in the floor pan and lay the seat rearward to access the module located under the seat. 4. Disconnect the memory seat/mirror module electrical connectors. Depress the retaining tab and pull straight apart. 5. Remove the module retaining bolts and remove the module from the bracket. INSTALLATION 1. Position and install the module retaining bolts. 2. Connect the memory seat/mirror module electrical connectors. 3. Position the drivers seat in the mounting holes in the floor pan. 4. Install the driver side front bucket seat retaining nuts from under the vehicle. 5. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Driver Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 9701 Memory Set Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 9702 Seat Memory Switch: Description and Operation Memory Switch Location Vehicles equipped with the memory system have a memory switch mounted to the driver side front door trim panel. This switch is used to set and recall all of the memory system settings for up to two drivers. The memory switch is a resistor multiplexed unit that is hard wired to the Body Control Module (BCM). The BCM sends out the memory system set and recall requests to the other electronic modules over the Programmable Communications Interface (PCI) data bus. The memory switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The memory switch has three momentary switch buttons labeled Set, 1 and 2. When the memory set switch is depressed, a resistance value is sent to the Body Control Module (BCM) via hard wired connections. When the memory system is in "set" mode a chime will be generated by the BCM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 9703 Seat Memory Switch: Testing and Inspection MEMORY SWITCH Memory Switch Test Table 1. Remove the memory switch from the drivers door panel. 2. Using an ohmmeter, check the continuity of the memory select switch MUX circuit between the C2 wire harness connector for the Body Control Module (BCM) and the wire harness connector for the memory switch. There should be continuity. If OK, go to Step 3. If not OK, repair the open or shorted MUX circuit as required. 3. Using an ohmmeter, check the continuity of the memory select switch return circuit between the C2 wire harness connector for the BCM and the wire harness connector for the memory switch. There should be continuity. If OK, go to Step 4. If not OK, repair the open or shorted return circuit as required. 4. Using an ohmmeter, test the resistances of the memory switch. If OK, refer to Body and Frame / Seats / Testing and Inspection. If not OK, replace the memory switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 9704 Seat Memory Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door trim panel switch bezel from the driver side front door. Using a thin flat-bladed pry tool, gently pry the switch bezel away from the drivers door trim panel. 3. Disconnect the memory switch wire harness connector from the memory switch. 4. Remove the two screws that secure the memory switch to the back of the driver side front door trim panel switch bezel. 5. Remove the memory switch. INSTALLATION 1. Position the memory switch and install and tighten the two screws that secure the memory switch to the back of the driver side front door trim panel switch bezel. Tighten the screws to 2.2 Nm (20 in. lbs.). 2. Reconnect the memory switch wire harness connector to the memory switch. 3. Install the trim panel switch bezel onto the driver side front door. 4. Reconnect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Description and Operation Power Seat Control Module: Description and Operation Vehicles equipped with heated seats utilize two heated seat modules. The heated seat modules are located under the front seats, where they are secured to the seat cushion pans. Each heated seat module has three connector receptacles that allow the modules to be connected to all of the required inputs and outputs through the seat wire harness. The heated seat modules are an electronic microprocessor controlled device designed and programmed to use inputs from the ignition switch, heated seat switch and the heated seat sensor to operate and control the heated seat elements in the front seat. The heated seat module operates on fused battery current received from the Integrated Power Module (IPM). The module is grounded at all times through the seat wire harness. Inputs to the module include a resistor multiplexed heated seat switch request circuit for the heated seat switch and the heated seat sensor inputs from the seat cushions of each front seat. In response to those inputs the heated seat module controls battery current feeds to the heated seat elements. When a heated seat switch request signal is received by the heated seat module and the enable input is high, the heated seat module energizes the selected heated seat sensor circuit and the sensor provides the module with an input indicating the surface temperature of the selected seat cushion. The Low heat set point is approximately 36° C (95° F), and the High heat set point is approximately 40° C (104° F). If the seat cushion surface temperature input is below the temperature set point for the selected temperature setting, the heated seat module energizes an N-channel Field Effect Transistor (N-FET) within the module which energizes the heated seat elements in the selected seat cushion and back. When the sensor input to the module indicates the correct temperature set point has been achieved, the module de-energizes the N-FET which de-energizes the heated seat elements. The heated seat module will continue to cycle the N-FET as needed to maintain the selected temperature set point. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Description and Operation > Page 9708 Power Seat Control Module: Testing and Inspection If a heated seat heats but one or both indicator lamps on the heated seat switch fail to operate, test the heated seat switch. If the heated seat switch checks OK, proceed as follows. 1. Check the heated seat element. 2. Check the heated seat sensor. 3. Using a voltmeter, back probe the appropriate heated seat module connector, do not disconnect. Check for battery voltage at the appropriate pin cavities. If OK go to Step 4. If not OK, repair the open or shorted voltage supply circuit as required. 4. Using a ohmmeter, back probe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK replace the heated seat module. If Not OK, repair the open or shorted ground circuit as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Description and Operation > Page 9709 Power Seat Control Module: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the appropriate front seat from the vehicle. 3. Unsnap the module from the seat cushion pan. 4. Disconnect the module wire harness connectors. INSTALLATION 1. Connect the module wire harness connectors. 2. Snap the module on the seat cushion pan. 3. Install the appropriate front seat in the vehicle. 4. Connect and isolate the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 9713 Power Seat Motor: Diagrams Driver Power Seat Front Riser Motor Driver Power Seat Horizontal Motor Driver Power Seat Rear Riser Motor Driver Power Seat Recliner Motor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Page 9714 Passenger Power Seat Front Riser Motor Passenger Power Seat Horizontal Motor Passenger Power Seat Rearriser Motor Passenger Power Seat Recliner Motor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Front Seat Track Power Adjuster Power Seat Motor: Service and Repair Front Seat Track Power Adjuster FRONT SEAT TRACK POWER ADJUSTER REMOVAL The power seat track and motors are serviced as an assembly. 1. Remove seat from vehicle. 2. Remove seat cushion. 3. Remove nut attaching recliner to seat back frame. 4. Remove both pivot bolts attaching seat back frame to seat track. 5. Remove seat back frame from recliner. 6. If power seat track is being replaced, transfer power recliner, wire harness and trim covers to replacement seat track. INSTALLATION The power seat track and motors are serviced as an assembly. 1. Install wire harness. 2. Place seat back in position. 3. Insert stud on seat back frame into recliner. 4. Install pivot bolts to hold seat back frame to seat track. Tighten bolts to 48 N.m (35 ft.lbs.) 5. Install nut attaching recliner to seat back frame. Tighten bolts to 12 N.m (105 in.lbs) 6. Install seat cushion. 7. Install seat in vehicle. Tighten fasteners to 60 N.m (44 ft.lbs.) torque. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Front Seat Track Power Adjuster > Page 9717 Power Seat Motor: Service and Repair Front Seat Track Adjuster / Power - OCS FRONT SEAT TRACK ADJUSTER / POWER - OCS REMOVAL WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid personal injury or death on vehicles equipped with the occupant classification system (OCS), only the occupant classification module (OCM) and the seat cushion trim may be serviced separately. All other components of the passenger side front seat cushion assembly must be serviced only as a complete factory-calibrated, assembled and tamper-evident service replacement package. This package includes the bladder, sensor, foam, wiring and a calibrated OCM. When installing this package always replace all of the existing components with the new components as a unit. Do not attempt to separate or disconnect any of the new OCS components in the service replacement package from each other, and do not attempt to reuse any of the replaced components in this or any other vehicle. Failure to take the proper precautions could result in failure of the passenger airbag to deploy when required, or in passenger airbag deployment when not required. The power seat track and motors are serviced as an assembly. 1. Remove seat from vehicle. 2. Remove seat cushion. 3. Remove nut attaching recliner to seat back frame. 4. Remove both pivot bolts attaching seat back frame to seat track. 5. Remove seat back frame from recliner. 6. If power seat track is being replaced, transfer power recliner, wire harness and trim covers to replacement seat track. INSTALLATION WARNING: To avoid personal injury or death, on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid personal injury or death on vehicles equipped with the occupant classification system (OCS), only the occupant classification module (OCM) and the seat cushion trim may be serviced separately. All other components of the passenger side front seat cushion assembly must be serviced only as a complete factory-calibrated, assembled and tamper-evident service replacement package. This package includes the bladder, sensor, foam, wiring and a calibrated OCM. When installing this package always replace all of the existing components with the new components as a unit. Do not attempt to separate or disconnect any of the new OCS components in the service replacement package from each other, and do not attempt to reuse any of the replaced components in this or any other vehicle. Failure to take the proper precautions could result in failure of the passenger airbag to deploy when required, or in passenger airbag deployment when not required. The power seat track and motors are serviced as an assembly. 1. Install wire harness. 2. Place seat back in position. 3. Insert stud on seat back frame into recliner. 4. Install pivot bolts to hold seat back frame to seat track. Tighten bolts to 48 N.m (35 ft.lbs) 5. Install nut attaching recliner to seat back frame. Tighten bolts to 12 N.m (105 in.lbs) 6. Install seat cushion. 7. Install seat in vehicle. Tighten fasteners to 88 N.m (65 ft.lbs.) torque. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor Position Sensor > Component Information > Diagrams Power Seat Motor Position Sensor: Diagrams Driver Power Seat Front Riser Position Sensor Driver Power Seat Horizontal Position Sensor Driver Power Seat Rear Riser Position Motor Driver Power Seat Recliner Position Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams Power Seat Switch: Diagrams Driver Power Seat Switch Passenger Power Seat Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 9724 Power Seat Switch: Description and Operation SEAT SWITCH Power Seat Switch Location Vehicles equipped with a driver side power seat utilize an eight-way power seat switch. Vehicles equipped with a passenger side power seat utilize a four-way power seat switch. These power seat switches features two knobs ganged together on the outboard seat cushion side shield. The switch is secured to the back of the seat cushion side shield with two screws. However, the control knobs for the seat switch unit must be removed before the seat switch can be removed from the side shield. The power seat switch cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. When a power seat switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 9725 Power Seat Switch: Testing and Inspection SEAT SWITCH 1. Remove the power seat switch. 2. Using an ohmmeter, check pin #1 of the power seat switch wire harness connector for continuity to ground. It should be present. If OK, go to Step 3. If not OK, repair the open ground circuit as required. 3. Using a voltmeter, check pin #5 of the power seat switch wire harness connector for battery current. It should be present. If OK, go to Step 4. If not OK, repair the open voltage supply circuit as required. Seat Switch Seat Switch Pin-Out 4. Using an ohmmeter, test the power seat switch for continuity, refer to SEAT SWITCH CONTINUITY TEST TABLE. If continuity is not present as indicated, replace the power seat switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 9726 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Removing Switch Control Knobs - Typical 2. Using a push pin remover or other suitable wide flat-bladed tool, gently pry the power seat and power recliner switch knobs off of the switch levers. 3. Remove the screws that secure the outboard seat cushion side cover to the seat cushion frame. 4. Pull the outboard seat cushion side cover away from the seat cushion frame far enough to access the power seat switch wire harness connector. 5. Disconnect the power seat wire harness connector from the power seat switch connector receptacle. 6. Remove the screws that secure the power seat switch to the inside of the outboard seat cushion side cover. 7. Remove the power seat switch from the outboard seat cushion side cover. INSTALLATION 1. Position the power seat switch onto the outboard seat cushion side cover. 2. Install and tighten the screws that secure the power seat switch to the inside of the outboard seat cushion side cover. Tighten the screws to 1.5 Nm (14 in. lbs.). 3. Reconnect the power seat wire harness connector to the power seat switch connector receptacle. 4. Install the outboard seat cushion side cover. 5. Install the power seat and power recliner switch knobs onto the switch control levers. 6. Reconnect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bladder > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bladder > Component Information > Locations > Page 9730 Seat Bladder: Description and Operation Seat Weight Bladder And Pressure Sensor - Typical Vehicles equipped with the Occupant Classification System (OCS) have a seat weight bladder and pressure sensor unit that is integral to the passenger front seat cushion. The bladder is sandwiched between the seat cushion pan and seat cushion foam. The bladder consists of two rectangular sheets of an elastomeric material and a molded plastic elbow fitting. The two sheets of material are sealed together around their perimeter and heat staked to each other at numerous regular points within their field. The elbow fitting is sealed to a small round hole in the lower surface of the bladder and is pointed downward where it passes through a clearance hole in the insulator pad and extends to just below the seat cushion. The bladder is then filled with a silicone fluid to become a pliable, quilted membrane. Under the seat cushion a short tube is securely clamped at one end to the bladder nipple, and at the other end to a nipple on the electronic pressure sensor. The sensor housing features an integral mount that snaps over a tab integral to the stamped steel Occupant Classification Module (OCM) mounting bracket welded to the underside of the passenger front seat cushion frame. The seat weight bladder and pressure sensor cannot be adjusted or repaired. The components of the passenger front seat cushion of a vehicle equipped with the OCS including the cushion frame, seat weight bladder and pressure sensor, seat cushion foam, wire harness and the OCM are serviced only as a factory-calibrated, assembled and tamper-evident unit. Only the OCM and the seat cushion trim are available for separate service replacement. Once a service replacement package has been installed in a vehicle, the OCM can thereafter be serviced only by replacing the entire passenger front seat cushion unit with another complete service replacement package. The seat weight bladder and pressure sensor unit is designed to sense the relative weight of a load applied to the passenger front seat cushion, which provides a logic input to the microprocessor of the Occupant Classification Module (OCM). When a load is applied to the seat cushion, fluid within the bladder becomes pressurized. These changes in bladder fluid pressure are measured by the pressure sensor under the seat cushion through the bladder tube. As the pressure within the bladder changes, the circuitry of the pressure sensor changes the output voltage of the sensor. The pressure sensor receives a nominal five volts and a ground through hard wired circuits from the OCM. The OCM then monitors the pressure sensor output voltage on the Programmable Communication Interface (PCI) data bus circuit. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior - 3rd Row Seat Front Leg Not Retracting Technical Service Bulletin # 23-012-06A Date: 060603 Interior - 3rd Row Seat Front Leg Not Retracting NUMBER: 23-012-06 REV. A GROUP: Body DATE: June 3, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-012-06, DATED FEBRUARY 25, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL YEARS AND A CORRECTED PARTS TABLE. SUBJECT: 3rd Row Seat Front Leg Will Not Retract OVERVIEW: This bulletin involves installing a new parts kit or spring on the 3rd row seat. MODELS: 2005 - **2007** (RS) Town & Country/Caravan 2005 - **2007** (RG) Chrysler Voyager SYMPTOM/CONDITION: The vehicle operator may describe that the front legs on the 3rd row bench seat will not retract. DIAGNOSIS: 1. Fold the seat into the floor. 2. If the front leg is 6 mm (0.25 in.) above the floor, check the vehicle built date. a. If the vehicle was built on or before September 16, 2004 (MDH 0916XX), proceed to Step # 3. b. If the vehicle was built on or after September 17, 2004 (MDH 0917XX), perform Repair Procedure B, using parts in Part Required: Table B. 3. Inspect the 3rd row bench seat mechanism for a damaged and/or broken cable. If the cable is damaged and/or broken, perform Repair Procedure A using the appropriate parts listed in Part Required: Table A. If the cable is not broken and/or damaged, further diagnosis is necessary. This bulletin does not apply. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior - 3rd Row Seat Front Leg Not Retracting > Page 9740 PARTS REQUIRED FOR VEHICLES BUILT ON OR BEFORE SEPT. 16, 2004. PARTS REQUIRED FOR VEHICLES BUILT ON OR AFTER SEPT. 17, 2004. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior - 3rd Row Seat Front Leg Not Retracting > Page 9741 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure A: For Vehicles Built On or Before Sept. 16, 2004 1. Remove the seat. Refer to the service information available on TechCONNECT, Section 23 Body, Seats, Seat, Removal, Seat - Third Row - Fold-In-Floor. 2. Place the seat assembly upside down in the folded seat back position on a clean bench surface. 3. Remove the inboard front leg cover trim screw. The screw is located on the inboard side of the inboard leg cover near where the leg latches to the floor. 4. Rotate the front inboard leg down into the stow position by hand. 5. Using a large screwdriver, remove the cover from the front leg by wedging the screwdriver between the top of the leg cover and the seat assembly and prying down, applying a lifting force on the cover. (Fig. 1). WARNING: The seat leg is spring loaded. Be careful when you release the leg that is being held down with your hand. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior - 3rd Row Seat Front Leg Not Retracting > Page 9742 6. Remove the rear seat to floor carpet cover by disengaging the clips, starting from the inboard clip and working towards the outboard clip (Fig. 2). CAUTION: Be careful removing the rear seat to floor carpet cover. Do not lift the cover to disengage the retaining clips. Doing so may break the clip tower off of the carpet cover. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior - 3rd Row Seat Front Leg Not Retracting > Page 9743 7. Remove the cable end clip by prying up on the base of the clip with a screwdriver (Fig. 4). 8. Remove the pulley by forcing the pulley toward the front of the seat. The pulley should pop out of it's grooves by tapping on the pulley using a screwdriver and a hammer (Fig. 5). 9. At the back of the seat, remove the eye clip from the spring, located in the rear leg. 10. Remove the spring from the rear foot. You may need to use a screwdriver to pop the spring out of the hook. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior - 3rd Row Seat Front Leg Not Retracting > Page 9744 11. Remove the cable from the retainer at the base of the rear foot by using a screwdriver to pry toward the open side of the retainer (Fig. 6). 12. If the seat has a tie strap securing the cable, proceed to Step # 14. If the seat has a bracket securing the cable, proceed to Step # 13 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior - 3rd Row Seat Front Leg Not Retracting > Page 9745 13. Pry the bracket open slightly so that the cable can be removed from the bracket. Proceed to Step # 15 14. Remove the tie strap securing the cable housing. Proceed to Step # 15. 15. Remove the cable from the seat. 16. Slide the bare wire of the new cable from the kit, through the retaining bracket. Make sure that the cable is oriented correctly with the eyelet hook towards the rear of the seat and the end clip toward the front of the seat. 17. Continue feeding the cable through the retaining bracket until the conduit is through. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior - 3rd Row Seat Front Leg Not Retracting > Page 9746 18. Feed the eyelet hook through the rear foot. The cable must run underneath the pivot shaft at the base, and then be fed up through the rear foot. Leave slack in the cable (Fig. 9). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior - 3rd Row Seat Front Leg Not Retracting > Page 9747 19. Attach the spring hook to the tip of the rear foot (Fig. 10). 20. Attach the cable eyelet hook to the empty hook on the spring, making sure that the cable is not bent or kinked (Fig. 11). 21. Attach the cable to the retainer at the base of the rear foot by using a screwdriver to pry into the open side of the retainer. 22. Attach the cable end clip by prying downward with a screwdriver on the end clip after it has been located on the outboard post of the inboard leg. Make sure that the head of the screwdriver is flush against the clip before pushing, because the clip will rotate on this post unless they are square to each other. 23. Insert the cable guide in the pulley holster and slide all the way down. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior - 3rd Row Seat Front Leg Not Retracting > Page 9748 24. Line up the cable between the pulley holsters and in the slot of the guide (Fig. 12). NOTE: If the cable guide is missing or damaged the new cable guide must be installed before the new pulley is installed. The cable guide and the pulley are not attached. Ensure that the tall part of the cable guide faces toward the rear of the seat. 25. Using a non-marking tool, push the pulley into the holsters, apply force toward the rear of the seat. The pulley will follow tracks in the holsters and pop into place. NOTE: Spray Mopar White Lithium Grease, p/n 04318066AB, on to the steel pulley, where the cable and the pulley contact each other. 26. If the seat had a tie strap securing the cable, proceed to Step # 28. If the seat has a bracket securing the cable, proceed to Step # 27 27. Place the cable in the bracket and pry the bracket closed (Fig. 7). Proceed to Step # 29 28. Install a tie strap, p/n 04856500, (Fig. 8). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior - 3rd Row Seat Front Leg Not Retracting > Page 9749 NOTE: If the front leg cover is not embossed with "Do Not Lift" as shown in (Fig. 13), replace all four front leg covers before continuing to the next step. 29. While holding the front leg at approximately a 20-45° angle, locate and slide the tip of the front leg cover onto the front leg (Fig. 14). 30. Push the leg down into the stow position and apply downward force until the cover snaps into place. 31. Install the inboard front leg cover trim screw. 32. Install the seat assembly in the vehicle. Refer to the service information available on TechCONNECT, Section 23 Body, Seats, Seat, Installation, Seat - Third Row - Fold-In-Floor. Repair Procedure B: Vehicles Built On or After Sept. 17, 2004 1. Fold all of the second and third row seats into the floor. 2. Remove the rear seat to floor carpet cover by disengaging the clips, starting from the inboard clip and working towards the outboard clip (Fig. 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior - 3rd Row Seat Front Leg Not Retracting > Page 9750 3. Place a trim stick, p/n C-4755 in each leg as shown to keep the legs from folding out of the seat (Fig. 15). 4. Rotate the seat up to approximately a 20450 angle so that the tension is removed from the spring and cable (Fig. 16). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior - 3rd Row Seat Front Leg Not Retracting > Page 9751 5. Using locking needle nose pliers, remove the spring from the floor attaching bracket. Once the bracket end is loose, remove the spring from the cable end. Continue holding the cable end. The seat must remain at the 20450 angle and the leg on the outboard side of the seat must be held down to keep slack in the cable (Fig. 17). 6. Attach the new spring, p/n 05174028AA, to the cable. 7. Attach the spring at the bracket. The seat must remain at the 20-45° angle and the leg on the outboard side of the seat must be held down to keep slack in the cable (Fig. 18) CAUTION: Do not use pliers to attach the spring to the bracket. Damage to the spring may occur. There should be enough slack in the cable to attach the spring Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > Customer Interest for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior - 3rd Row Seat Front Leg Not Retracting > Page 9752 using your hands. 8. Fold the seat down into the floor. 9. Remove both trim sticks from the legs. 10. Install the floor carpet cover. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior 3rd Row Seat Front Leg Not Retracting Technical Service Bulletin # 23-012-06A Date: 060603 Interior - 3rd Row Seat Front Leg Not Retracting NUMBER: 23-012-06 REV. A GROUP: Body DATE: June 3, 2006 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-012-06, DATED FEBRUARY 25, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL YEARS AND A CORRECTED PARTS TABLE. SUBJECT: 3rd Row Seat Front Leg Will Not Retract OVERVIEW: This bulletin involves installing a new parts kit or spring on the 3rd row seat. MODELS: 2005 - **2007** (RS) Town & Country/Caravan 2005 - **2007** (RG) Chrysler Voyager SYMPTOM/CONDITION: The vehicle operator may describe that the front legs on the 3rd row bench seat will not retract. DIAGNOSIS: 1. Fold the seat into the floor. 2. If the front leg is 6 mm (0.25 in.) above the floor, check the vehicle built date. a. If the vehicle was built on or before September 16, 2004 (MDH 0916XX), proceed to Step # 3. b. If the vehicle was built on or after September 17, 2004 (MDH 0917XX), perform Repair Procedure B, using parts in Part Required: Table B. 3. Inspect the 3rd row bench seat mechanism for a damaged and/or broken cable. If the cable is damaged and/or broken, perform Repair Procedure A using the appropriate parts listed in Part Required: Table A. If the cable is not broken and/or damaged, further diagnosis is necessary. This bulletin does not apply. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior 3rd Row Seat Front Leg Not Retracting > Page 9758 PARTS REQUIRED FOR VEHICLES BUILT ON OR BEFORE SEPT. 16, 2004. PARTS REQUIRED FOR VEHICLES BUILT ON OR AFTER SEPT. 17, 2004. POLICY: Reimbursable within the provisions of the warranty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior 3rd Row Seat Front Leg Not Retracting > Page 9759 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure A: For Vehicles Built On or Before Sept. 16, 2004 1. Remove the seat. Refer to the service information available on TechCONNECT, Section 23 Body, Seats, Seat, Removal, Seat - Third Row - Fold-In-Floor. 2. Place the seat assembly upside down in the folded seat back position on a clean bench surface. 3. Remove the inboard front leg cover trim screw. The screw is located on the inboard side of the inboard leg cover near where the leg latches to the floor. 4. Rotate the front inboard leg down into the stow position by hand. 5. Using a large screwdriver, remove the cover from the front leg by wedging the screwdriver between the top of the leg cover and the seat assembly and prying down, applying a lifting force on the cover. (Fig. 1). WARNING: The seat leg is spring loaded. Be careful when you release the leg that is being held down with your hand. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior 3rd Row Seat Front Leg Not Retracting > Page 9760 6. Remove the rear seat to floor carpet cover by disengaging the clips, starting from the inboard clip and working towards the outboard clip (Fig. 2). CAUTION: Be careful removing the rear seat to floor carpet cover. Do not lift the cover to disengage the retaining clips. Doing so may break the clip tower off of the carpet cover. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior 3rd Row Seat Front Leg Not Retracting > Page 9761 7. Remove the cable end clip by prying up on the base of the clip with a screwdriver (Fig. 4). 8. Remove the pulley by forcing the pulley toward the front of the seat. The pulley should pop out of it's grooves by tapping on the pulley using a screwdriver and a hammer (Fig. 5). 9. At the back of the seat, remove the eye clip from the spring, located in the rear leg. 10. Remove the spring from the rear foot. You may need to use a screwdriver to pop the spring out of the hook. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior 3rd Row Seat Front Leg Not Retracting > Page 9762 11. Remove the cable from the retainer at the base of the rear foot by using a screwdriver to pry toward the open side of the retainer (Fig. 6). 12. If the seat has a tie strap securing the cable, proceed to Step # 14. If the seat has a bracket securing the cable, proceed to Step # 13 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior 3rd Row Seat Front Leg Not Retracting > Page 9763 13. Pry the bracket open slightly so that the cable can be removed from the bracket. Proceed to Step # 15 14. Remove the tie strap securing the cable housing. Proceed to Step # 15. 15. Remove the cable from the seat. 16. Slide the bare wire of the new cable from the kit, through the retaining bracket. Make sure that the cable is oriented correctly with the eyelet hook towards the rear of the seat and the end clip toward the front of the seat. 17. Continue feeding the cable through the retaining bracket until the conduit is through. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior 3rd Row Seat Front Leg Not Retracting > Page 9764 18. Feed the eyelet hook through the rear foot. The cable must run underneath the pivot shaft at the base, and then be fed up through the rear foot. Leave slack in the cable (Fig. 9). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior 3rd Row Seat Front Leg Not Retracting > Page 9765 19. Attach the spring hook to the tip of the rear foot (Fig. 10). 20. Attach the cable eyelet hook to the empty hook on the spring, making sure that the cable is not bent or kinked (Fig. 11). 21. Attach the cable to the retainer at the base of the rear foot by using a screwdriver to pry into the open side of the retainer. 22. Attach the cable end clip by prying downward with a screwdriver on the end clip after it has been located on the outboard post of the inboard leg. Make sure that the head of the screwdriver is flush against the clip before pushing, because the clip will rotate on this post unless they are square to each other. 23. Insert the cable guide in the pulley holster and slide all the way down. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior 3rd Row Seat Front Leg Not Retracting > Page 9766 24. Line up the cable between the pulley holsters and in the slot of the guide (Fig. 12). NOTE: If the cable guide is missing or damaged the new cable guide must be installed before the new pulley is installed. The cable guide and the pulley are not attached. Ensure that the tall part of the cable guide faces toward the rear of the seat. 25. Using a non-marking tool, push the pulley into the holsters, apply force toward the rear of the seat. The pulley will follow tracks in the holsters and pop into place. NOTE: Spray Mopar White Lithium Grease, p/n 04318066AB, on to the steel pulley, where the cable and the pulley contact each other. 26. If the seat had a tie strap securing the cable, proceed to Step # 28. If the seat has a bracket securing the cable, proceed to Step # 27 27. Place the cable in the bracket and pry the bracket closed (Fig. 7). Proceed to Step # 29 28. Install a tie strap, p/n 04856500, (Fig. 8). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior 3rd Row Seat Front Leg Not Retracting > Page 9767 NOTE: If the front leg cover is not embossed with "Do Not Lift" as shown in (Fig. 13), replace all four front leg covers before continuing to the next step. 29. While holding the front leg at approximately a 20-45° angle, locate and slide the tip of the front leg cover onto the front leg (Fig. 14). 30. Push the leg down into the stow position and apply downward force until the cover snaps into place. 31. Install the inboard front leg cover trim screw. 32. Install the seat assembly in the vehicle. Refer to the service information available on TechCONNECT, Section 23 Body, Seats, Seat, Installation, Seat - Third Row - Fold-In-Floor. Repair Procedure B: Vehicles Built On or After Sept. 17, 2004 1. Fold all of the second and third row seats into the floor. 2. Remove the rear seat to floor carpet cover by disengaging the clips, starting from the inboard clip and working towards the outboard clip (Fig. 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior 3rd Row Seat Front Leg Not Retracting > Page 9768 3. Place a trim stick, p/n C-4755 in each leg as shown to keep the legs from folding out of the seat (Fig. 15). 4. Rotate the seat up to approximately a 20450 angle so that the tension is removed from the spring and cable (Fig. 16). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior 3rd Row Seat Front Leg Not Retracting > Page 9769 5. Using locking needle nose pliers, remove the spring from the floor attaching bracket. Once the bracket end is loose, remove the spring from the cable end. Continue holding the cable end. The seat must remain at the 20450 angle and the leg on the outboard side of the seat must be held down to keep slack in the cable (Fig. 17). 6. Attach the new spring, p/n 05174028AA, to the cable. 7. Attach the spring at the bracket. The seat must remain at the 20-45° angle and the leg on the outboard side of the seat must be held down to keep slack in the cable (Fig. 18) CAUTION: Do not use pliers to attach the spring to the bracket. Damage to the spring may occur. There should be enough slack in the cable to attach the spring Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Bottom > Seat Bottom Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Bottom Frame: > 23-012-06A > Jun > 06 > Interior 3rd Row Seat Front Leg Not Retracting > Page 9770 using your hands. 8. Fold the seat down into the floor. 9. Remove both trim sticks from the legs. 10. Install the floor carpet cover. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Connector Views Seat Heater: Connector Views Driver Heated Seat Back Driver Heated Seat Cushion Passenger Heated Seat Back Passenger Heated Seat Cushion Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seat System Seat Heater: Description and Operation Heated Seat System Heated Seat Switch Locations Vehicles with the heated seat option can be visually identified by the two separate heated seat switches located in the instrument panel center stack, just above the radio. The heated seat system allows the front seat driver and passenger to select from two different levels of supplemental electrical seat heating (HI/LO), or no seat heating to suit their individual comfort requirements. The heated seat system for this vehicle includes the following major components: - Heated Seat Elements - Four heated seat elements are used per vehicle, two for each front seat. One heated seat element is integral to each front seat trim cover, one in the seat back and one in the seat bottom (cushion). Service replacement heating elements are available. - Heated Seat Modules - Two heated seat modules are used per vehicle. One module is mounted to each of the seat cushion pans, located under the forward edge of each front seat. - Heated Seat Sensors - Two heated seat sensors are used per vehicle, one for each front seat. The heated seat sensors are integral to each of the heated seat bottoms (cushions). - Heated Seat Switch- Two heated seat switches are used per vehicle, one for the driver and one for the passenger side front seats. The switches are mounted in the instrument panel center stack. Hard wired circuitry connects the heated seat system components to each other through the electrical system of the vehicle. These circuits may be connected to each other, to the vehicle electrical system and to the heated seat system components through the use of a combination of soldered splices and splice block connectors. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. The heated seat system components operate on battery current received through a fuse in the Integrated Power Module (IPM) on a fused ignition switch output (run) circuit from the Body Control Module (BCM). The system will only operate when the ignition switch is in the On position. The heated seat system will be turned Off automatically whenever the ignition switch is turned to any position except On. Also, the heated seat system will not operate when the surface temperature of the seat cushion cover at either heated seat sensor is above the designed temperature set points of the system. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seat System > Page 9777 Seat Heater: Description and Operation Heated Seat Element The heated seat system includes two seat heating elements in each front seat, one for the seat cushion and the other for the seat back. The two elements for each seat are connected in parallel with the Heated Seat Module (HSM). The temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. One temperature sensor is used for each seat, and it is located on the seat cushion heating element for all models. The seat heating elements are attached to the seat cushion foam and seat back foam units. The heated seat elements and the temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, the seat element assembly must be replaced. The heated seat elements resist the flow of electrical current. When battery current is passed through the elements, the resistance of the elements to the current flow is released in the form of heat. The temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. When the temperature of the seat cushion cover rises, the resistance of the sensor decreases. The heated seat module supplies a five-volt signal to one side of each sensor, and monitors the voltage drop through the sensor on a return circuit. The heated seat module uses this temperature sensor input to monitor the temperature of the seat, and regulates the current flow to the seat heating elements accordingly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat Element Seat Heater: Testing and Inspection Heated Seat Element The wire harness connectors for the seat cushion and seat back heating elements are located under the seat, at the main seat harness. In order to access and test the heated seat elements it will be necessary to remove the appropriate front seat retaining bolts and lay the seat rearward, up against one of the rear seats. It is not necessary to disconnect the seat electrical connectors, just use care not to damage the attached wire harnesses while testing For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. NOTE: When checking heated seat elements for continuity, be certain to move the heating element being checked. Moving the element, such as sitting in the seat will eliminate the possibility of an intermittent open in the element which would only be evident if the element was in a certain position. Failure to check the element in various positions could result in an incomplete test. SEAT CUSHION ELEMENT 1. From under the vehicle, remove the appropriate seats four retaining nuts. 2. From inside the vehicle, pull the seat up, off the mounting studs and lay it back, up against one of the rear seats. 3. Locate and disconnect the black 4-way electrical connector, connected to the main seat harness. 4. Check for continuity between the two circuit cavities labeled "A" and "D" of the wire harness connector (Red & Black wires). There should be continuity. If OK, refer to Body Control Module for complete system testing procedures. See: Body Control Systems/Body Control Module/Testing and Inspection If not OK, install a replacement heated seat cushion element SEAT BACK ELEMENT 1. From under the vehicle, remove the appropriate seats four retaining nuts. 2. From inside the vehicle, pull the seat up and off the mounting studs and lay it back, up against one of the rear seats. 3. Locate and disconnect the green 2-way electrical connector, connected to the main seat harness. 4. Check for continuity between the two circuit cavities of the 2-way wire harness connector. There should be continuity. If OK, refer to Body Control Module for complete system testing procedures. See: Body Control Systems/Body Control Module/Testing and Inspection If not OK, install a replacement heated seat back element. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Heated Seat Element > Page 9780 Seat Heater: Testing and Inspection Heated Seat System The most efficient means of diagnosing the heated seat system is by individual component. For diagnosis of a specific component refer to the following: - Heated seat module - Heated seat elements - Heated seat switch - Heated seat sensor Refer to Diagrams for complete circuit schematic or connector pin-out information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Page 9781 Seat Heater: Service and Repair HEATED SEAT ELEMENTS REMOVAL NOTE: Do not remove the factory installed heating elements from the seat or seat back cushions. The original element is permanently attached and cannot be removed without permanent damage. The replacement heating element is designed to be applied directly on top of the factory installed heating element. 1. Disconnect and isolate the battery negative cable. 2. Remove the appropriate seat cushion or seat back trim cover. 3. Disconnect the inoperative heated seat cushion or seat back element electrical connectors. 4. Locate the wires leading from the inoperative heating element and cut them off flush with the edge of the original heating element. INSTALLATION Heating Element Installation - Early Build Vehicles Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Page 9782 Heating Element Installation - Late Build Vehicles 1. Peel off the adhesive backing on the back of the replacement heating element and stick directly on top of the factory installed heating element. CAUTION: During the installation of the replacement heating element, be careful not to fold or crease the element assembly. Folds or creases will cause premature failure. Heated Seat Wire Harness Routing - Early Build Vehicles Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Page 9783 Heated Seat Wire Harness Routing - Late Build Vehicles 2. Connect the new heating element electrical connectors. Passenger seat shown, driver seat similar. 3. Connect the battery negative cable. 4. Verify heated seat system operation. 5. Install the appropriate seat cushion or seat back trim cover. NOTE: Make certain the seat wire harness is correctly routed through the seat and seat back. The excess wire between the cushion and back elements should be securely tucked between the rear of the cushion foam and the rear carpet flap of the trim cover. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams Seat Heater Control Module: Diagrams Driver Heated Seat Module C1 Driver Heated Seat Module C2 Driver Heated Seat Module C3 Passenger Heated Seat Module (Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams > Page 9787 Passenger Heated Seat Module C1 (Export) Passenger Heated Seat Module C2 (Export) Passenger Heated Seat Module C3 (Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Description and Operation Seat Heater Sensor: Description and Operation Two heated seat sensors are used per vehicle, one in each front seat cushion heating element. The heated seat temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. The heated seat sensors cannot be repaired or adjusted and if found to be faulty, the complete heated seat cushion element must be replaced. The temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. When the temperature of the seat cushion cover rises, the resistance of the sensor decreases. The heated seat module supplies a five-volt current to one side of each sensor, and monitors the voltage drop through the sensor on a return circuit. The heated seat module uses this temperature sensor input to monitor the temperature of the seat, and regulates the current flow to the seat heating elements accordingly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Sensor > Component Information > Description and Operation > Page 9791 Seat Heater Sensor: Testing and Inspection NOTE: When checking heated seat elements for continuity, be certain to move the heating element being checked. Moving the element, such as sitting in the seat will eliminate the possibility of an intermittent open in the element which would only be evident if the element was in a certain position. Failure to check the element in various positions could result in an incomplete test. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. Disconnect the black 4-way cushion heating element wire harness connector. 2. Using an ohmmeter, check the resistance between cavities "B" and "C". The sensor resistance should be between 50 kilohms at 15° C (60° F) and 2 kilohms at 30° C (85° F). If not OK, replace the faulty seat element and sensor assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation Seat Heater Switch: Description and Operation Heated Seat Switch Location The heated seat switches are mounted in the instrument panel center bezel. The two three-position rocker-type switches, one switch for each front seat, are incorporated into one large switch assembly that also includes the hazard, rear window wiper and washer switches. Each heated seat switch provides a resistor multiplexed signal to its respective Heated Seat Module (HSM) through separate hard wired circuits. Each switch has an Off, Low, and High position so that both the driver and the front seat passenger can select a preferred seat heating mode. Each switch has two Light-Emitting Diodes (LED) which light to indicate that the heater for the seat is turned on. The heated seat switches and their LEDs cannot be repaired. If either switch or LED is faulty or damaged, the entire switch assembly must be replaced. There are three positions that can be selected with each of the heated seat switches: Off, Low, or High. When the left side of the switch rocker is fully depressed, the Low position is selected and the low position LED indicator illuminates. When the right side of the switch rocker is fully depressed, the High position is selected and the high position LED indicator illuminates. When the switch rocker is moved to its neutral position (middle), Off is selected and both LED indicators are extinguished. Each switch provides separate resistor, hard wire inputs to its respective Heated Seat Module (HSM) to indicate the selected switch position. The heated seat module responds to the heated seat switch status messages by controlling the output to the seat heater elements of the selected seat. The Low heat position set point is about 36° C (97° F), and the High heat position set point is about 40° C (105° F). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Page 9795 Seat Heater Switch: Testing and Inspection DRIVER HEATED SEAT SWITCH Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. WARNING: REFER TO THE RESTRAINTS OF THIS MANUAL BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. CHECKING SWITCH SIGNAL AND WIRING AT THE MODULE - EARLY BUILD VEHICLES 1. Disconnect and isolate the battery negative cable. 2. Access and disconnect the gray 4-way connector from the heated seat module. Visually inspect wiring terminals for damage that would prevent positive connection. If not OK, repair or replace the necessary components. 3. Connect the battery negative cable. Place the heated seat switch in the LO position. Using an Ohmmeter, check the resistance between cavities 2 and 3 of the gray connector noted above. Resistance should be about 3.5 kilohms (3500 ohms). If not OK, check resistance directly at switch, as noted below. If OK, proceed to the next step. If not OK, replace the faulty switch. 4. Place the heated seat switch in the HI position. Using an ohmmeter, check the resistance between cavities 2 and 3 of the gray connector noted above. Resistance should be about 1.4 kilohms (1400 ohms). If not OK, check resistance directly at the switch, as indicated in the Heated Seat Switch Test Table. If OK, proceed. If not OK replace the faulty switch. 5. With the system ON in the HI position, check for battery voltage and ground at cavities 4 and 1. If OK, proceed with testing remaining components. If not OK, repair open or shorted wiring. CHECKING SWITCH SIGNAL AND WIRING AT THE MODULE - LATE BUILD VEHICLES 1. Disconnect and isolate the battery negative cable. 2. Access and disconnect the black 8-way connector from the main seat harness. Visually inspect wiring terminals for damage that would prevent positive connection. If not OK, repair or replace the necessary components. 3. Connect the battery negative cable. Place the heated seat switch in the LO position. Using an Ohmmeter, check the resistance between cavities 3 and 5 of the black 8-way connector noted above. Resistance should be about 3.5 kilohms (3500 ohms). If not OK, check resistance directly at switch, as noted below. If OK, proceed to the next step. If not OK, replace the faulty switch. 4. Place the heated seat switch in the HI position. Using an ohmmeter, check the resistance between cavities 3 and 5 of the black 8-way connector noted above. Resistance should be about 1.4 kilohms (1400 ohms). If not OK, check resistance directly at the switch, as indicated in the Heated Seat Switch Test Table. If OK, proceed. If not OK replace the faulty switch. 5. With the system ON in the HI position, check for battery voltage and ground at cavities 4 and 5. If OK, proceed with testing remaining components. If not OK, repair open or shorted wiring. CHECKING SWITCH ONLY 1. Disconnect and isolate the battery negative cable. Remove the center bezel from the instrument panel. Check for continuity between the ground circuit cavity (#10) of the instrument panel center bezel switch electrical connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground as required. 2. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the instrument panel center bezel switch electrical connector (#4). If OK, turn the ignition switch to the Off position, and go to Step 3. If not OK, repair the open fused ignition switch output (run) circuit as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Page 9796 Instrument Panel Center Bezel Switch Connector Switch Retaining Screws 3. Test the heated seat switch as shown in the Heated Seat Switch Test chart and the connector pin-out below. If OK, go to Step 4. If not OK, replace the instrument panel center bezel switch assembly. 4. Connect the instrument panel center bezel switch and test the heated seat system for proper operation. If the system is still inoperative proceed with checking remaining components. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Page 9797 Seat Heater Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO THE RESTRAINTS OF THIS MANUAL BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. Switch Retaining Screws 3. Remove the three screws that secure the heated seat switch to the back of the instrument panel center bezel. 4. Remove the heated seat switch from the back of the instrument panel center bezel. INSTALLATION 1. Position the heated seat switch onto the back of the instrument panel center bezel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Page 9798 Switch Retaining Screws 2. Install and tighten the three screws that secure the heated seat switch to the back of the instrument panel center bezel. Tighten the screws to 1.5 N.m (13 in. lbs.). 3. Install the center bezel onto the instrument panel. 4. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation Seat Track: Description and Operation POWER SEAT TRACK The power seat option includes an electrically operated power seat track located under the front seat. If equipped with Memory System, the front power seat track on the driver side of the vehicle also provides the mounting location for the Memory Seat/Mirror Module (MSMM). The power seat circuit breakers are mounted on the rear of the power seat track, just behind the seat rear trim panel. The lower half of the power seat track is secured to the floor panel via four studs and nuts that must be accessed from the underside of the vehicle. Four bolts secure the bottom of the seat cushion pan to the upper half of the power seat track unit. Four additional bolts secure the seat back frame to the power seat track unit. The eight-way power seat track unit includes four reversible electric motors that are secured to the upper half of the track unit. Each motor moves the seat adjuster through a combination of worm-drive gearboxes and screw-type drive units. Each of the four power seat track motors used on models equipped with the optional memory system incorporate a position potentiometer integral to the motor assembly, which electronically monitors the motor position. This enables the memory system to function by referencing the motor positions programmed into the memory seat/mirror module. The front and rear of the seat are operated by two separate vertical adjustment motors. These motors can be operated independently of each other, tilting the entire seat assembly forward or rearward. They can also be operated in unison by selecting the proper power seat switch functions, which will raise or lower the entire seat assembly. A third motor is the horizontal adjustment motor, which moves the seat track in the forward and aft directions. The forth motor is the recliner adjustment motor, which moves the seat back in the forward and rearward directions. The four-way power seat track unit includes two reversible electric motors that are secured to the upper half of the track unit. Each motor moves the seat adjuster through a combination of worm-drive gearboxes and screw-type drive units. The horizontal adjustment motor moves the seat track in the forward and aft directions. The recliner adjustment motor moves the seat back in the forward and rearward directions. The power seat track unit cannot be repaired, and is serviced only as a complete unit. If any component in this unit is faulty or damaged, the entire power seat track unit must be replaced. When the power seat switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation > Page 9802 Seat Track: Testing and Inspection POWER SEAT TRACK WARNING: SOME VEHICLES ARE EQUIPPED WITH SEATBACK MOUNTED AIRBAGS. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. Actuate the power seat switch to move the power seat track adjusters in each direction. The power seat track adjusters should move in each of the selected directions. If a power seat track adjuster operates in one direction only, move the adjuster a short distance in the opposite direction and test again to be certain that the adjuster is not at its travel limit. If the power seat track adjuster still operates in one direction only. If the power seat track adjuster does not operate in more than one direction, perform the following tests. TESTING POWER SEAT TRACK MOTORS 1. Check the power seat circuit breaker under the seat. If OK, go to Step 2. If not OK, replace the faulty power seat circuit breaker. 2. Check for battery voltage at the power seat circuit breaker under the seat. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the fuse in the Integrated Power Module (IPM) as required. 3. Remove the outboard seat cushion side cover. Disconnect the wire harness connector from the power seat switch. Check for battery voltage at the fused B(+) circuit cavity of the power seat switch wire harness connector. If OK, go to Step 4. If not OK, repair the open fused B(+) circuit to the power seat circuit breaker under the seat as required. 4. Check for continuity between the ground circuit cavity of the power seat switch wire harness connector and a known good ground. There should be continuity. If OK, go to Step 5. If not OK, repair the open ground circuit as required. 5. Test the power seat switch. If the switch tests OK, test the circuits of the power seat wire harness between the inoperative power seat track adjuster motor and the power seat switch for shorts or opens. If the circuits check OK, replace the faulty power seat track unit. If the circuits are not OK, repair the power seat wire harness as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Description and Operation > Page 9803 Seat Track: Service and Repair POWER SEAT TRACK REMOVAL WARNING: SOME VEHICLES ARE EQUIPPED WITH SEATBACK MOUNTED AIRBAGS. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE. THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the appropriate seat from the vehicle and place it on a clean work surface. 3. Remove the Memory Seat/Mirror Module (MSMM) mounting fasteners (if equipped). 4. Disconnect the MSMM electrical harness connectors and remove the MSMM from the power seat track (if equipped). 5. Remove the front seat track rear cover. 6. Remove the seat side cover and power seat switch as an assembly. 7. Disconnect all electrical connectors connecting the power seat track to the seat assembly. 8. Pull the seat back trim cover up slightly to access and remove the two seat back frame mounting bolts and also remove two seat back recliner bolts. 9. Remove four seat track mounting bolts from the seat cushion pan. 10. Remove the power seat track from the seat. INSTALLATION 1. Position the seat cushion on the seat track. 2. Install the four seat track retaining bolts in the seat cushion pan. Torque the bolts to 28.5 Nm (21 ft-lbs.). 3. Position the seat back and install the two seat back frame mounting bolts and the two seat back recliner bolts. Torque the bolts to 55 Nm (40.5 ft-lbs.). 4. Route and connect the electrical connectors between the power seat track and the seat assembly. 5. Install the seat side cover and power seat switch as an assembly. 6. Install the front seat track rear cover. 7. Position the Memory Seat/Mirror Module (MSMM) and connect the MSMM electrical connectors (if equipped). 8. Install the MSMM mounting fasteners (if equipped). 9. Install the seat assembly in the vehicle. 10. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations > Page 9808 Left Cylinder Lock Switch (EXport) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations > Page 9809 Door Lock Cylinder Switch: Description and Operation The Door Cylinder Lock Switch (If equipped) is used to: - Unlock/Lock all the doors via the Central Locking feature. - Arm/Disarm the Vehicle Theft Security System. - Trigger the Illuminated Entry feature. The door cylinder lock switch is mounted to the rear of the driver door lock cylinder. When installed on the rear of the cylinder, there is a tab on the lock cylinder that aligns with the switch to prevent it from turning. An anti-rotating device. The door cylinder lock switch is a one time use switch. Once it is removed from the rear of the door lock cylinder, it may not be reinstalled and a new switch must be used. When the Door Cylinder Lock Switch is turned either way using the door key cylinder, the BCM reads a direct message signal from the switch. If turning the key cylinder once, toward the front of the vehicle, this will: 1. Mechanically unlock the door lock. 2. Disarm the Vehicle Theft Security System (if equipped). 3. Turn on the Illuminated Entry (if equipped) for approximately 30 seconds. If the key cylinder is turned to the unlock position (toward the front of vehicle) twice within two seconds, all the doors and liftgate will unlock (if equipped with the central locking feature). To lock the vehicle using the door cylinder lock switch, turn the key cylinder toward the rear of the vehicle once. This will lock the door that you are using the key on. If equipped with the central locking feature, this will lock all the other doors and liftgate. Furthermore, this will arm the vehicle theft security system and turn off the illuminated entry. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations > Page 9810 Door Lock Cylinder Switch: Testing and Inspection Door Cylinder Lock Switch Resistance Any diagnosis of the power lock system should begin with the use of the DRB III (R) diagnostic tool. 1. Visually inspect the switch for proper installation. Make sure it is seated on the rear of the key cylinder, with the tab of the door key cylinder properly aligned with the slot on the door cylinder lock switch. 2. Disconnect the switch at the harness connector and check the resistance in each switch position. CAUTION: Do not disconnect the switch from the rear of the door key cylinder. This switch is a one time use switch. Once it is removed from the rear of the switch, it is not reusable and must be replaced. Test the switch at the harness connector. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Locations > Page 9811 Door Lock Cylinder Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel of the effected door cylinder lock switch. 3. Close the door window. 4. Disconnect the door cylinder lock switch wire connector from the door harness, and wiring clip from the impact beam. 5. Remove the outer door handle from the door. 6. Remove the switch from the key cylinder in the door handle and remove from vehicle. INSTALLATION 1. Install the switch on the key cylinder in the door handle. 2. Install the door handle. 3. Connect the door cylinder lock switch wire connector to the door harness, and the wiring clip to the impact beam. 4. Install the door trim panel of the affected door cylinder lock switch. 5. Connect the battery negative cable. 6. Verify system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component Locations Hood Sensor/Switch (For Alarm): Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Component Locations > Page 9817 Left Side Engine Compartment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 9818 Hood Sensor/Switch (For Alarm): Service and Repair HOOD AJAR SWITCH-EXPORT REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a small flat blade screwdriver, pry trigger switch from the bracket on the left fender well. 3. Disconnect the hood ajar switch from the wire connector and remove from vehicle. INSTALLATION 1. Connect the hood ajar switch to the wire connector. 2. Press the hood ajar switch into position on the bracket located on the left inner fender well. 3. Reconnect the battery negative cable. 4. Close the hood and check for proper operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Diagrams Adjustable Pedals Sensor (Memory Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 9825 Adjustable Pedals Switch (Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 9826 Pedal Positioning Switch: Service and Repair ADJUSTABLE PEDALS SWITCH REMOVAL The adjustable pedals switch is located in the steering column lower shroud. Remove the shroud, then remove the switch. INSTALLATION The adjustable pedals switch is located in the steering column lower shroud. Install the switch in the shroud, then install the shroud. Once installed, test for proper operation of the adjustable pedals. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Component Locations Power Door Lock Switch: Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Component Locations > Page 9831 Passenger Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 9832 Power Door Lock Switch: Diagrams Driver Door Lock Switch Passenger Door Lock Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 9833 Power Door Lock Switch: Testing and Inspection Door Lock Switch Continuity 1. Remove door trim panel. 2. Disconnect wire connector from back of door lock switch. 3. Depress switch to LOCK position. Door Lock Switch 4. Using an ohmmeter, test switch resistance between Pins 2 and 3. 5. Depress switch to UNLOCK position. 6. Test resistance between Pins 2 and 3. 7. Test resistance between pins 2 and 3 while switch is in its normal unactuated mode. 8. If resistance values are not within the parameters shown replace the door lock switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 9834 Power Door Lock Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove door trim panel. 3. Disconnect wire connector from back of door lock switch. 4. Remove two screws to door lock switch. 5. Remove switch from vehicle. INSTALLATION 1. Install the switch into the vehicle. 2. Install the two screws to door lock switch. 3. Connect wire connector to back of door lock switch. 4. Install door trim panel. 5. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Right Side Instrument Panel Lower RHD Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9838 Power Mirror Switch: Diagrams Power Folding Mirror Switch (Export) Power Mirror Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9839 Power Mirror Switch: Description and Operation POWER FOLDAWAY MIRROR SWITCH-EXPORT Power Foldway Mirror Switch These vehicles may be equipped with Power Fold-away Mirrors. This feature allows both the driver and passenger side view mirrors to fold inward (retract) on demand. The vehicle has an additional switch located on the steering column that controls the folding function of the mirror assembly. The fold-away side view mirror is attached to the vehicle's door in the same manner as mirrors without the fold-away option. The fold-away mirrors unique option is the internal motor which allows the mirrors to fold inward on demand. The fold-away mirror motor is not serviceable separately and if a motor is found to be faulty the entire side view mirror must be replaced. When the mirror retract switch is depressed, both of the side view mirrors will fold inward, Thus making the overall width of the vehicle the smallest possible. This can be helpful were parking space is a absolute minimum. When the driver's door is opened, only the driver's door mirror will unfold. If the passenger door is opened, both mirrors will unfold. The power fold away mirror system consists of the following components: mirror switch, side view mirror, relay, wires and fuse. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9840 Power Mirror Switch: Testing and Inspection REMOTE SWITCH Mirror Switch Test Part 1 Mirror Switch Test Part 2 1. Remove power mirror switch. 2. Disconnect wiring harness at switch connector. Mirror Switch 3. Using a ohmmeter, test for continuity between the terminals of the switch. 4. If results shown in the table are not obtained, replace the switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Foldaway Mirror Switch- Export Power Mirror Switch: Service and Repair Power Foldaway Mirror Switch- Export REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the upper and lower steering column shroud. 3. Disconnect electrical harness connector. Power Folding Mirror Switch 4. Remove switch from steering column shroud. INSTALLATION 1. Install switch to steering column shroud. 2. Connect wire harness connector. 3. Install the upper and lower steering column shroud. 4. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Foldaway Mirror Switch- Export > Page 9843 Power Mirror Switch: Service and Repair Remote Switch REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel lower cover. 3. From behind headlamp switch assembly, depress retaining tabs and push switch from instrument panel. 4. Disconnect wire connector from power mirror switch. 5. Disengage lock tabs above and below the mirror switch. 6. Remove power mirror switch from headlamp switch bezel. INSTALLATION 1. Install power mirror switch to the headlamp switch bezel. 2. Connect wire connector to the power mirror switch. 3. Insert headlamp switch assembly into instrument panel. 4. Install instrument panel lower cover. 5. Connect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Motor Position Sensor > Component Information > Diagrams Power Seat Motor Position Sensor: Diagrams Driver Power Seat Front Riser Position Sensor Driver Power Seat Horizontal Position Sensor Driver Power Seat Rear Riser Position Motor Driver Power Seat Recliner Position Sensor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Power Seat Switch: Diagrams Driver Power Seat Switch Passenger Power Seat Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 9850 Power Seat Switch: Description and Operation SEAT SWITCH Power Seat Switch Location Vehicles equipped with a driver side power seat utilize an eight-way power seat switch. Vehicles equipped with a passenger side power seat utilize a four-way power seat switch. These power seat switches features two knobs ganged together on the outboard seat cushion side shield. The switch is secured to the back of the seat cushion side shield with two screws. However, the control knobs for the seat switch unit must be removed before the seat switch can be removed from the side shield. The power seat switch cannot be repaired. If one switch is damaged or faulty, the entire power seat switch unit must be replaced. When a power seat switch control knob or knobs are actuated, a battery feed and a ground path are applied through the switch contacts to the power seat track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker must not be allowed to continue, or the motor may be damaged. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 9851 Power Seat Switch: Testing and Inspection SEAT SWITCH 1. Remove the power seat switch. 2. Using an ohmmeter, check pin #1 of the power seat switch wire harness connector for continuity to ground. It should be present. If OK, go to Step 3. If not OK, repair the open ground circuit as required. 3. Using a voltmeter, check pin #5 of the power seat switch wire harness connector for battery current. It should be present. If OK, go to Step 4. If not OK, repair the open voltage supply circuit as required. Seat Switch Seat Switch Pin-Out 4. Using an ohmmeter, test the power seat switch for continuity, refer to SEAT SWITCH CONTINUITY TEST TABLE. If continuity is not present as indicated, replace the power seat switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 9852 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Removing Switch Control Knobs - Typical 2. Using a push pin remover or other suitable wide flat-bladed tool, gently pry the power seat and power recliner switch knobs off of the switch levers. 3. Remove the screws that secure the outboard seat cushion side cover to the seat cushion frame. 4. Pull the outboard seat cushion side cover away from the seat cushion frame far enough to access the power seat switch wire harness connector. 5. Disconnect the power seat wire harness connector from the power seat switch connector receptacle. 6. Remove the screws that secure the power seat switch to the inside of the outboard seat cushion side cover. 7. Remove the power seat switch from the outboard seat cushion side cover. INSTALLATION 1. Position the power seat switch onto the outboard seat cushion side cover. 2. Install and tighten the screws that secure the power seat switch to the inside of the outboard seat cushion side cover. Tighten the screws to 1.5 Nm (14 in. lbs.). 3. Reconnect the power seat wire harness connector to the power seat switch connector receptacle. 4. Install the outboard seat cushion side cover. 5. Install the power seat and power recliner switch knobs onto the switch control levers. 6. Reconnect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Locations > Page 9856 Power Sliding Door Switch: Diagrams Left B.Pillar Switch (Power Sliding Door) Left Full Open Switch (Power Sliding Door) Right B.Pillar Switch (power Sliding Door) Right Full Open Switch (Power Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Locations > Page 9857 Right Sliding Door Latch Sensing Switch (Power Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Description and Operation > Full Open Switch Power Sliding Door Switch: Description and Operation Full Open Switch Full Open Switch Position And Orientation The full open switch is located in the hold open latch under the sliding door lower hinge. When the power sliding door control module receives a ground signal input from the full open switch, and as long as the cinching latch actuator is not in power mode or the handle switch is open, the signal indicates that the door is at the full open position. The full open switch is incorporated into the hold open latch. If the full open switch is inoperative, the entire hold open latch assembly must be replaced. The full open switch is triggered by a pawl lever in the hold open latch. When the full open switch is closed (circuit to ground) the ratchet has engaged on the hold open striker and the pawl lever has engaged on the ratchet, locking the latch from opening and holding the door in the full open position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Description and Operation > Full Open Switch > Page 9860 Power Sliding Door Switch: Description and Operation B-Pillar Switch The B-pillar switches are located on the interior of the vehicle, on the B-pillar trim panels. These switches serve as an open and close command switch for the appropriate power sliding door. When the B-pillar switch is depressed a signal is sent to the Body Control Module (BCM), this signal is then sent to the power sliding door control module, telling it to start a power open or close cycle. The child lockout feature must be disabled and the sliding door must be unlocked in order for the B-pillar switch to function. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Sliding Door Switch > Component Information > Description and Operation > Page 9861 Power Sliding Door Switch: Service and Repair B-PILLAR SWITCH REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick (special tool # C-4755) or equivalent, gently pry the leading upper edge of the B-pillar switch away from the B-pillar trim. 3. Once the upper edge is free from B-pillar trim, rock the switch out of the switch opening. 4. Disconnect the B-pillar switch electrical connector. First, slide the connector lock away from the switch then, depress connector retaining tab while pulling straight apart. 5. Remove the B-pillar switch from the vehicle. INSTALLATION 1. Connect the B-pillar switch electrical connector. Slide connector lock toward the switch to lock in place. 2. Hook the lower edge of the B-pillar switch on the B-pillar trim and then push the switch firmly into position. 3. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Locations > Page 9865 Power Trunk / Liftgate Hazard Sensor: Description and Operation Pinch sensors are located on each side of the lift-gate. These sensors look like weather-strips, however they consist of pieces of electrically conductive rubber (tapeswitch), wires, resistor, double sided tape, and a plastic carrier. They are used to indicate an obstruction during a power liftgate close cycle. During a power liftgate close cycle, if either of the two conductive rubber strips (tapeswitch) of the pinch sensor come in contact with an obstacle, the pinch sensor circuit is completed. This tells the power liftgate control module that a obstruction is felt. The control module will stop the liftgate immediately and return it to the full open position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Locations > Page 9866 Power Trunk / Liftgate Hazard Sensor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove trim panel from liftgate. Pinch Sensor Location 3. Disconnect the pinch sensor wire harness connector. 4. Remove screws holding the pinch sensor to lift-gate. 5. Feed the pinch sensor wire harness out of the liftgate and remove the sensor from the vehicle. INSTALLATION WARNING: USE EXTREME CAUTION WHEN TESTING PINCH SENSOR OPERATION. CAUTION: Ensure liftgate surface is clean and dry prior to pinch sensor installation. Failure to do so will inhibit the adhesive backings ability to adhere to the liftgate and cause improper system operation or premature component failure. 1. Position the pinch sensor to the liftgate. 2. Install the third screw from the top of the sensor first. Do not torque screw at this time. 3. Install the remaining three screws holding the sensor to the liftgate. Torque all screws to 25 in. lbs. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Locations > Page 9867 Pinch Sensor Location 4. Install wire harness grommet in liftgate flange and route, connect the pinch sensor wire harness connector. 5. Remove protective tape from the top of the pinch sensor. Firmly apply pressure to the sensor adhesive to secure it to the liftgate. 6. Install the trim panel on the liftgate. 7. Connect the battery negative cable. 8. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes related to the pinch sensor. 9. Verify power liftgate system and pinch sensor operation. Cycle the power liftgate through one complete open and close cycle, during the final close cycle press the pinch sensor to verify the power liftgate detects an obstruction and returns to the full open position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 9871 Power Trunk / Liftgate Lock Switch: Diagrams Liftgate Ajar Switch (Manual Release) Liftgate Ajar Switch (power Release) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation Seat Heater Sensor: Description and Operation Two heated seat sensors are used per vehicle, one in each front seat cushion heating element. The heated seat temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. The heated seat sensors cannot be repaired or adjusted and if found to be faulty, the complete heated seat cushion element must be replaced. The temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. When the temperature of the seat cushion cover rises, the resistance of the sensor decreases. The heated seat module supplies a five-volt current to one side of each sensor, and monitors the voltage drop through the sensor on a return circuit. The heated seat module uses this temperature sensor input to monitor the temperature of the seat, and regulates the current flow to the seat heating elements accordingly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Sensor > Component Information > Description and Operation > Page 9875 Seat Heater Sensor: Testing and Inspection NOTE: When checking heated seat elements for continuity, be certain to move the heating element being checked. Moving the element, such as sitting in the seat will eliminate the possibility of an intermittent open in the element which would only be evident if the element was in a certain position. Failure to check the element in various positions could result in an incomplete test. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the battery negative cable. Disconnect the black 4-way cushion heating element wire harness connector. 2. Using an ohmmeter, check the resistance between cavities "B" and "C". The sensor resistance should be between 50 kilohms at 15° C (60° F) and 2 kilohms at 30° C (85° F). If not OK, replace the faulty seat element and sensor assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation Seat Heater Switch: Description and Operation Heated Seat Switch Location The heated seat switches are mounted in the instrument panel center bezel. The two three-position rocker-type switches, one switch for each front seat, are incorporated into one large switch assembly that also includes the hazard, rear window wiper and washer switches. Each heated seat switch provides a resistor multiplexed signal to its respective Heated Seat Module (HSM) through separate hard wired circuits. Each switch has an Off, Low, and High position so that both the driver and the front seat passenger can select a preferred seat heating mode. Each switch has two Light-Emitting Diodes (LED) which light to indicate that the heater for the seat is turned on. The heated seat switches and their LEDs cannot be repaired. If either switch or LED is faulty or damaged, the entire switch assembly must be replaced. There are three positions that can be selected with each of the heated seat switches: Off, Low, or High. When the left side of the switch rocker is fully depressed, the Low position is selected and the low position LED indicator illuminates. When the right side of the switch rocker is fully depressed, the High position is selected and the high position LED indicator illuminates. When the switch rocker is moved to its neutral position (middle), Off is selected and both LED indicators are extinguished. Each switch provides separate resistor, hard wire inputs to its respective Heated Seat Module (HSM) to indicate the selected switch position. The heated seat module responds to the heated seat switch status messages by controlling the output to the seat heater elements of the selected seat. The Low heat position set point is about 36° C (97° F), and the High heat position set point is about 40° C (105° F). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 9879 Seat Heater Switch: Testing and Inspection DRIVER HEATED SEAT SWITCH Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. WARNING: REFER TO THE RESTRAINTS OF THIS MANUAL BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. CHECKING SWITCH SIGNAL AND WIRING AT THE MODULE - EARLY BUILD VEHICLES 1. Disconnect and isolate the battery negative cable. 2. Access and disconnect the gray 4-way connector from the heated seat module. Visually inspect wiring terminals for damage that would prevent positive connection. If not OK, repair or replace the necessary components. 3. Connect the battery negative cable. Place the heated seat switch in the LO position. Using an Ohmmeter, check the resistance between cavities 2 and 3 of the gray connector noted above. Resistance should be about 3.5 kilohms (3500 ohms). If not OK, check resistance directly at switch, as noted below. If OK, proceed to the next step. If not OK, replace the faulty switch. 4. Place the heated seat switch in the HI position. Using an ohmmeter, check the resistance between cavities 2 and 3 of the gray connector noted above. Resistance should be about 1.4 kilohms (1400 ohms). If not OK, check resistance directly at the switch, as indicated in the Heated Seat Switch Test Table. If OK, proceed. If not OK replace the faulty switch. 5. With the system ON in the HI position, check for battery voltage and ground at cavities 4 and 1. If OK, proceed with testing remaining components. If not OK, repair open or shorted wiring. CHECKING SWITCH SIGNAL AND WIRING AT THE MODULE - LATE BUILD VEHICLES 1. Disconnect and isolate the battery negative cable. 2. Access and disconnect the black 8-way connector from the main seat harness. Visually inspect wiring terminals for damage that would prevent positive connection. If not OK, repair or replace the necessary components. 3. Connect the battery negative cable. Place the heated seat switch in the LO position. Using an Ohmmeter, check the resistance between cavities 3 and 5 of the black 8-way connector noted above. Resistance should be about 3.5 kilohms (3500 ohms). If not OK, check resistance directly at switch, as noted below. If OK, proceed to the next step. If not OK, replace the faulty switch. 4. Place the heated seat switch in the HI position. Using an ohmmeter, check the resistance between cavities 3 and 5 of the black 8-way connector noted above. Resistance should be about 1.4 kilohms (1400 ohms). If not OK, check resistance directly at the switch, as indicated in the Heated Seat Switch Test Table. If OK, proceed. If not OK replace the faulty switch. 5. With the system ON in the HI position, check for battery voltage and ground at cavities 4 and 5. If OK, proceed with testing remaining components. If not OK, repair open or shorted wiring. CHECKING SWITCH ONLY 1. Disconnect and isolate the battery negative cable. Remove the center bezel from the instrument panel. Check for continuity between the ground circuit cavity (#10) of the instrument panel center bezel switch electrical connector and a good ground. There should be continuity. If OK, go to Step 2. If not OK, repair the open ground circuit to ground as required. 2. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the instrument panel center bezel switch electrical connector (#4). If OK, turn the ignition switch to the Off position, and go to Step 3. If not OK, repair the open fused ignition switch output (run) circuit as required. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 9880 Instrument Panel Center Bezel Switch Connector Switch Retaining Screws 3. Test the heated seat switch as shown in the Heated Seat Switch Test chart and the connector pin-out below. If OK, go to Step 4. If not OK, replace the instrument panel center bezel switch assembly. 4. Connect the instrument panel center bezel switch and test the heated seat system for proper operation. If the system is still inoperative proceed with checking remaining components. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 9881 Seat Heater Switch: Service and Repair REMOVAL WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO THE RESTRAINTS OF THIS MANUAL BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel center bezel. Switch Retaining Screws 3. Remove the three screws that secure the heated seat switch to the back of the instrument panel center bezel. 4. Remove the heated seat switch from the back of the instrument panel center bezel. INSTALLATION 1. Position the heated seat switch onto the back of the instrument panel center bezel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 9882 Switch Retaining Screws 2. Install and tighten the three screws that secure the heated seat switch to the back of the instrument panel center bezel. Tighten the screws to 1.5 N.m (13 in. lbs.). 3. Install the center bezel onto the instrument panel. 4. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations Driver Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 9886 Memory Set Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 9887 Seat Memory Switch: Description and Operation Memory Switch Location Vehicles equipped with the memory system have a memory switch mounted to the driver side front door trim panel. This switch is used to set and recall all of the memory system settings for up to two drivers. The memory switch is a resistor multiplexed unit that is hard wired to the Body Control Module (BCM). The BCM sends out the memory system set and recall requests to the other electronic modules over the Programmable Communications Interface (PCI) data bus. The memory switch cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. The memory switch has three momentary switch buttons labeled Set, 1 and 2. When the memory set switch is depressed, a resistance value is sent to the Body Control Module (BCM) via hard wired connections. When the memory system is in "set" mode a chime will be generated by the BCM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 9888 Seat Memory Switch: Testing and Inspection MEMORY SWITCH Memory Switch Test Table 1. Remove the memory switch from the drivers door panel. 2. Using an ohmmeter, check the continuity of the memory select switch MUX circuit between the C2 wire harness connector for the Body Control Module (BCM) and the wire harness connector for the memory switch. There should be continuity. If OK, go to Step 3. If not OK, repair the open or shorted MUX circuit as required. 3. Using an ohmmeter, check the continuity of the memory select switch return circuit between the C2 wire harness connector for the BCM and the wire harness connector for the memory switch. There should be continuity. If OK, go to Step 4. If not OK, repair the open or shorted return circuit as required. 4. Using an ohmmeter, test the resistances of the memory switch. If OK, refer to Body and Frame / Seats / Testing and Inspection. If not OK, replace the memory switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 9889 Seat Memory Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the front door trim panel switch bezel from the driver side front door. Using a thin flat-bladed pry tool, gently pry the switch bezel away from the drivers door trim panel. 3. Disconnect the memory switch wire harness connector from the memory switch. 4. Remove the two screws that secure the memory switch to the back of the driver side front door trim panel switch bezel. 5. Remove the memory switch. INSTALLATION 1. Position the memory switch and install and tighten the two screws that secure the memory switch to the back of the driver side front door trim panel switch bezel. Tighten the screws to 2.2 Nm (20 in. lbs.). 2. Reconnect the memory switch wire harness connector to the memory switch. 3. Install the trim panel switch bezel onto the driver side front door. 4. Reconnect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams Sunroof Module (Except Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 9893 Sunroof / Moonroof Switch: Description and Operation Power Sunroof Switch The power sunroof switch is a combination pushbutton and rocker switch mounted in the overhead console. The sunroof switch is a direct contact unit that is directly wired to the sunroof motor/ module assembly. The sunroof switch performs the following functions: - Power sunroof open - Power sunroof closed - Power sunroof vent The sunroof is electrically operated from two switches located on the windshield header, rearward of the map lamp. The "VENT" switch is a push button type switch and opens the sunroof to the vent position only. The other switch "OPEN/CLOSED" is a rocker type switch for opening and closing the sunroof. Pressing and releasing the open button once, the sunroof will express open and the wind deflector will raise. If the button is pressed a second time the sunroof will stop in that position. Pressing and holding the close button will close the sunroof. If the close button is released the sunroof will stop in that position. The switch is grounded at one terminal and receives a 12 volt signal from the sunroof motor/module on the remaining three terminals. The switch pulls down the 12 volt reference voltage from the motor/ module signaling it to perform the desired function. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 9894 Sunroof / Moonroof Switch: Testing and Inspection The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Perform the following test prior to switch replacement. 1. Remove the overhead console. 2. Disconnect the power sunroof switch wire harness connector. 3. With the ignition key in the "RUN" position check for battery voltage on the "OPEN", "CLOSE" and "VENT" circuits of the sunroof switch harness connector. If OK, go to Step 4. If not OK, inspect the wiring harness and connectors between the motor/ module and switch for damage and repair as necessary. 4. With the ignition key in the "OFF" position check for continuity between the ground circuit of the sunroof switch harness connector and a known good ground. Continuity should be present. If OK, go to Step 5. If not OK, inspect the wiring harness and connector and repair the ground circuit as necessary. Sunroof Switch Pinout Power Sunroof Switch Continuity Table 5. Using an ohmmeter, test the continuity of the power sunroof switch in each switch position. If OK, inspect the wiring harness and connectors for damage and repair as necessary. If not OK, replace the power sunroof switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 9895 Sunroof / Moonroof Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Overhead Console 2. Separate the overhead console from the head-liner, by carefully pulling down on the front portion, toward the windshield, to release the retaining clips. 3. Release the sunroof switch retaining tab, disconnect the electrical connector and remove the switch from the overhead console. INSTALLATION Overhead Console 1. Position the sunroof switch against the overhead console and push the switch to properly seat in retaining clip. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 9896 2. Install the overhead console assembly. 3. Connect the battery negative cable. 4. Confirm proper sunroof system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Description and Operation > Exterior Handle Switch Trunk / Liftgate Switch: Description and Operation Exterior Handle Switch The exterior handle switch is an electronic release switch mounted to the rear license plate lamp housing assembly, located just above the license plate. This switch controls the power liftgate release function and is also capable of reversing the power lift-gate when it is in motion. A full power open cycle cannot be performed using this switch, only one of the power open command switches (key fob and overhead console mounted) can be used to perform a full power open cycle. The exterior handle switch is a serviceable component. When the exterior handle switch is depressed, with the liftgate in the closed position, a message is sent to the Body Control Module (BCM). The BCM then sends a signal to the power liftgate control module via the Programmable Communication Interface (PCI) data bus circuit. The power liftgate control module then sends a signal to the power latch mounted actuator, which moves the liftgate from the primary closed and latched position to the open and movable position. If the liftgate is not pulled open once the latch releases within a few seconds, the latch will cinch closed again. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Description and Operation > Exterior Handle Switch > Page 9901 Trunk / Liftgate Switch: Description and Operation Full Open Switch Full Open Switch Location The full open switch is located on the gear motor housing and is used to signal the power lift-gate control module when the power liftgate is in the full open position. Two wires are used from the full open switch contacts to the gear motor assemblies main electrical connector. The full open switch is a serviceable component. When the power liftgate reaches the full open position, the gear motor housing mounted full open switch electrical contacts close. This sends a ground signal to the power liftgate control module, telling the module that the liftgate has reached the full open position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Exterior Handle Switch Trunk / Liftgate Switch: Service and Repair Exterior Handle Switch REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the liftgate and remove the liftgate trim panel. 3. Remove the rear lamp bar assembly from the vehicle. 4. Locate the two wires going to the exterior handle switch. Cut the tie strap and trace the wires to the large electrical connector and back the wires out of the large connector and through the grommet. Take care to mark the location of the wire terminals in relation to the large connector so that they are positioned in the appropriate cavities upon switch installation. Rear Light Bar 5. Depress the two exterior handle switch retaining tabs and roll the switch out of the light bar assembly. INSTALLATION Rear Light Bar 1. Install the handle switch in the light bar assembly. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Exterior Handle Switch > Page 9904 2. Locate the two wires going to the exterior handle switch. Install the wires through the grommet and in the large connector. Secure with a tie strap. NOTE: Be certain wires are reinstalled in the correct wire cavities. Failure to do so could result in damage to the handle switch. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. 3. Install the rear light bar. 4. Install the liftgate trim panel. 5. Connect the battery negative cable. 6. Using an appropriate scan tool, check any erase any power liftgate control module diagnostic trouble codes. 7. Verify power liftgate system and handle switch operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Exterior Handle Switch > Page 9905 Trunk / Liftgate Switch: Service and Repair Full Open Switch REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the lift gear and link rod assembly from the vehicle 3. Cut the two wires leading to the full open switch or back the wires out of the electrical connector. 4. Remove the full open switch retaining screw and remove the full open switch from the gear motor housing assembly. INSTALLATION 1. Perform a wiring repair on the full open switch wires following the approved procedure in the Wiring section. Or install new terminals on the wire ends and reinstall in the main lift-gate motor electrical connector. 2. Position and install the full open switch retaining screw. 3. Install the power liftgate lift gear and link rod assembly. 4. Connect the battery negative cable. 5. Using an appropriate scan tool, check any erase any power liftgate control module diagnostic trouble codes. 6. Verify power liftgate system and full open switch operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair COWL GRILLE REMOVAL 1. Remove wiper arms. Fig. 6 2. Remove four (4) screws securing cowl cover to wiper module (Fig. 6). 3. Disengage quarter turn fasteners at outboard ends of cowl grill from body. 4. Release hood latch and open hood. CAUTION: To prevent hood scratching of cowl grille before removal, cover outboard exterior ends of cowl grille with masking tape or equivalent method. NOTE: Do not over bend cowl grille during removal. Bend cowl grille just enough to clear top of wiper pivot shaft and bottom rear corner of hood. 5. Remove cowl grill by raising above driver side wiper pivot shaft and swinging away towards engine compartment. The cowl grille will need to be bent on outboard end to clear simultaneously top of wiper pivot shaft and bottom corner of hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 9911 Fig. 7 6. Close hood. Do not latch. Remove outboard screws. (Fig. 7). 7. Disconnect washer hose in line connector. 8. Disconnect washer hose and grommet from hole in wiper module and pull out. 9. Remove cowl grille by raising over opposite wiper pivot shaft and removing away from vehicle. 10. Remove cowl cover from vehicle. INSTALLATION 1. Reverse removal procedure. 2. When installing cowl cover over wiper module, make sure fore aft locator on the underside of cowl grill seat into the locator grooves on top of wiper module. 3. Start all cowl grille mounting screws by hand before torquing to specifications. 4. Assure washer hose is properly routed and not pinched. 5. Center cowl grille to body and windshield. 6. Assure "arrow" indicator head of quarter turn fasteners is pointing toward windshield. 7. Tighten screw to 1.2 N.m (11 in.lbs.) torque. 8. Install the wiper arms. 9. Check for proper spray pattern from washer nozzles. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair Front Door Weatherstrip: Service and Repair FRONT DOOR WEATHERSTRIP REMOVAL 1. Open front door. Fig. 2 2. Using fork tool (C-4829), remove push pin fasteners attaching front door weatherstrip to end frames and bottom of door (Fig. 2). 3. Pull weatherstrip from retaining channel around window frame. 4. Remove weatherstrip from vehicle. INSTALLATION 1. Position weatherstrip on door. 2. Install push pin fasteners attaching front door weatherstrip to end frames and bottom of door (Fig. 2). 3. Install weatherstrip into retaining channel around window frame. 4. Close front door. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Molding FRONT DOOR OUTER BELT MOLDING REMOVAL 1. Remove the side view mirror. 2. Remove door trim panel. 3. Roll door glass down. Fig. 1 4. Using a hook tool, disengage interlocking lip at the base of the inward edge of the belt molding (Fig. 1). 5. Remove belt molding from door. INSTALLATION 1. Place belt molding in position on door (Fig. 1). NOTE: Make sure end of applique is against outer belt. 2. Engage interlocking lip at the base of the inward edge of the belt molding on door panel. 3. Install door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 9920 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove door frame closeout moldings. 2. Pull weatherstrip from glass run channel at rear of door frame, working from the bottom to the top. 3. Disengage clip attaching weatherstrip to door frame. Fig. 1 4. Pull weatherstrip from lip along top of door frame (Fig. 1). 5. Remove door trim panel. 6. Remove door speaker, if equipped. 7. Remove watershed as necessary to gain access to screw attaching front lower corner of glass run weatherstrip to inner door panel. 8. Remove screw attaching glass run weatherstrip to inner door panel. 9. Remove inner belt weatherstrip. 10. Pull weatherstrip from front glass run channel. 11. Remove glass run weatherstrip from vehicle. INSTALLATION 1. Position glass run weatherstrip on vehicle (Fig.1). 2. Insert A-pillar section of the glass run into door through belt line and lower to bottom of door using molded corners as a guide. NOTE: Care must be taken not to damage the medal bracket when installing through the belt opening. 3. Locate the top corner portion of the B-pillar glass run section onto the roll frame and slide it up until the part bottoms out on the header portion of the roll frame. NOTE: Do not JAM the corner into place. 4. Install the entire B-pillar glass run onto roll frame. 5. Working from the B-pillar forward install the first eight to twelve inches of the header glass run onto the roll frame. NOTE: Use care not to push or pull the header section and the molded corner out of location. 6. Install fully the entire A-pillar glass run section by indexing the molded corner detail into the roll frame. Slide the glass run up the A-pillar until Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 9921 the rubber molded joint just touches the roll frame. 7. Verify that the tertiary seal is on the correct side of the roll frame prior to seating the glass run fully onto the frame. Verify the glass runs is fully seated for the header, and A-pillar and B-pillar 8. Install screw attaching glass run weatherstrip to inner door panel. 9. Install inner belt weatherstrip. 10. Install watershed. 11. Push weatherstrip groove onto lip along top of door frame. 12. Engage clip into slot in door frame. 13. Push weatherstrip into channel at rear of door frame, working from the top to bottom. 14. Install door frame closeout moldings. 15. Install door speaker, if equipped. 16. Install door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 9922 Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Molding FRONT DOOR INNER BELT MOLDING REMOVAL 1. Remove door trim panel. 2. Peel upper corner seals away form inner belt molding to clear removal path. Fig. 1 3. Pull inner belt molding upward to disengage retaining channel in bottom of molding from door panel flange (Fig. 1). 4. Remove inner belt molding from vehicle. INSTALLATION 1. Place inner belt molding in position on door (Fig. 1). 2. Push inner belt molding downward to engage retaining channel onto door panel flange. 3. Install upper corner seals in proper location. 4. Install door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Sliding Door Weatherstrip > Component Information > Service and Repair Sliding Door Weatherstrip: Service and Repair SLIDING DOOR WEATHERSTRIP REMOVAL 1. Open sliding door. 2. Remove door opening sill plate. 3. Loosen B-pillar trim covers. 4. Loosen quarter panel trim panels. 5. From splice at the bottom center of door opening, pull weatherstrip from pinch flange around door opening. INSTALLATION 1. Place splice at the bottom center of door opening, pushing weatherstrip onto pinch flange around door opening. 2. Tighten quarter panel trim panels. 3. Tighten B-pillar trim covers. 4. Install door opening sill plate. 5. Close sliding and check alignment. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Component Locations Speed Control Servo Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Component Locations > Page 9931 Cruise Control Servo: Connector Locations 3.3-3.8 Liter Engine Rear Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Component Locations > Page 9932 3.3-3.8 Liter Engine Front Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 9933 Speed Control Servo (Gas) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 9934 Cruise Control Servo: Description and Operation The servo unit consists of a solenoid valve body, and a vacuum chamber. The solenoid valve body contains three solenoids: - Vacuum - Vent - Dump The vacuum chamber contains a diaphragm with a cable attached to control the throttle linkage. The PCM controls the solenoid valve body. The solenoid valve body controls the application and release of vacuum to the diaphragm of the vacuum servo. The servo unit cannot be repaired and is serviced only as a complete assembly Power is supplied to the servo by the PCM through the brake switch. The PCM controls the ground path for the vacuum and vent solenoids. The dump solenoid is energized anytime it receives power. If power to the dump solenoid is interrupted, the solenoid dumps vacuum in the servo. This provides a safety backup to the vent and vacuum solenoids. The vacuum and vent solenoids must be grounded by the PCM to operate. When the PCM grounds the vacuum servo solenoid, the solenoid allows vacuum to enter the servo and pull open the throttle plate using the cable. When the PCM breaks the ground, the solenoid closes and no more vacuum is allowed to enter the servo. The PCM also operates the vent solenoid via ground. The vent solenoid opens and closes a passage to bleed or hold vacuum in the servo as required. The PCM cycles the vacuum and vent solenoids to maintain the set speed, or to accelerate and decelerate the vehicle. To increase throttle opening, the PCM grounds the vacuum and vent solenoids. To decrease throttle opening, the PCM removes the grounds from the vacuum and vent solenoids. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 9935 Cruise Control Servo: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. Disconnect the negative battery cable. Fig.2 Speed Control Cable End 3. Disconnect the throttle and speed control cable ends from throttle body. 4. Depress lock tabs holding speed control and throttle cable casing to cable mount bracket. 5. Disconnect vacuum line from speed control servo that leads to the battery tray/vacuum reservoir. Fig.3 Battery Tray/Vacuum Reservoir 6. Remove battery tray/vacuum reservoir, refer to the Battery section for more information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 9936 Fig.4 Speed Control Servo 7. Remove speed control servo and bracket. 8. Disconnect wire connector from speed control servo. 9. Remove speed control servo. INSTALLATION Transfer speed control cable to replacement speed control servo. 1. Install retaining clip to cable at servo. 2. Install 2 nuts at cable to servo and servo bracket, tighten to 7 Nm (60 in. lbs.). 3. Connect electrical connector to servo. 4. Connect vacuum line to speed control servo that leads to the battery tray/vacuum reservoir. 5. Install speed control servo and bracket. 6. Install battery tray/vacuum reservoir, refer to the Battery section for more information. 7. Install speed control and throttle cable casing to cable mount bracket. 8. Connect the throttle and speed control cable ends to throttle body. 9. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation Cruise Control Servo Cable: Description and Operation The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle body control linkage. This cable causes the throttle control linkage to open or close the throttle valve in response to movement of the vacuum servo diaphragm. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and Operation > Page 9940 Cruise Control Servo Cable: Service and Repair REMOVAL 1. Disconnect the negative battery cable. 2. Remove speed control cable from throttle cam by sliding clasp out hole used for throttle cable. 3. Compress the retaining tabs on the cable and slide cable out of bracket. 4. Disconnect electrical connectors and vacuum hose from servo. 5. Remove two nuts attaching speed control cable and mounting bracket to servo. 6. Pull cable away from servo to expose retaining clip and remove clip attaching cable to servo. 7. Remove speed control cable. INSTALLATION 1. Slide cable into throttle cable bracket and engage retaining tabs. 2. Rotate the throttle cam forward to the wide open position and install speed control cable clasp. 3. Rotate the throttle cam forward to the wide open position and install throttle cable clasp. 4. Install retaining clip that attaches cable to servo. 5. Insert servo studs through holes in the mounting bracket and speed control cable. 6. Install nuts, tighten to 6.7 Nm (60 in. lbs.). 7. Connect vacuum hose to servo. 8. Connect electrical connector. 9. Install servo and bracket and tighten nuts and bolt 10. Connect negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Speed Control Switches Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 9944 Cruise Control Switch: Diagrams Left Speed Control Switch Right Speed Control Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 9945 Cruise Control Switch: Service Precautions WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO THE RESTRAINT SYSTEMS SECTION FOR MORE INFORMATION. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 9946 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system and are located on the steering wheel. The speed control system has five separate resistive switches that provide a single multiplexed (MUX) voltage inputs to the PCM.The switch names are: ON, OFF, SET, COAST, RESUME, ACCEL, TAPUP COAST, and CANCEL. Based on conditions when the buttons are pushed (and released), the five voltages ranges provided to the PCM result in the following functions: ON, OFF, SET, COAST, RESUME, ACCEL, TAP-UP TAP-DOWN, COAST, and CANCEL. Refer to the Speed Control Section for more information Also the PCM receives an input from the brake switch to sense whether the brake pedal has been depressed. When the PCM receives the brake depressed input, it turns OFF power to the speed control servo and disengages speed control. Also the power to the servo is supplied through the brake switch, which opens the circuit when the brake pedal is depressed. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 9947 Cruise Control Switch: Service and Repair REMOVAL The speed control switches are mounted in the steering wheel and wired through the clock spring device under the airbag module. WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO THE RESTRAINT SYSTEMS SECTION FOR MORE INFORMATION. 1. Remove the negative battery cable. 2. Turn OFF ignition. 3. Remove the air bag, refer to the restraint section for more information. 4. Remove the screw from bottom of the switch. 5. Remove switch from steering wheel. 6. Disconnect two-way electrical connector. 7. Repeat for the other switch. INSTALLATION The speed control switches are mounted in the steering wheel and wired through the clock spring device under the airbag module. WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO THE RESTRAINT SYSTEMS SECTION FOR MORE INFORMATION. 1. Connect two-way electrical connector. 2. Install switch. 3. Install screw for the switch. 4. Repeat for the other switch. 5. Install the air bag, refer to the restraint section for more information. 6. Install the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Locations Cruise Control Vacuum Reservoir: Locations The vacuum reservoir is located in the engine compartment. It is made of plastic. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Locations > Page 9951 Cruise Control Vacuum Reservoir: Description and Operation The vacuum reservoir is located in the engine compartment. It is made of plastic. The reservoir stores engine vacuum. Manifold vacuum is supplied from the brake booster check valve. The speed control vacuum supply hose has a check valve at the source (brake booster) to maintain the highest available vacuum level in the servo, reservoir and vacuum hoses. When engine vacuum drops, as in climbing a grade while driving, the reservoir supplies the vacuum needed to maintain proper speed control operation. The vacuum reservoir cannot be repaired and must be replaced if faulty. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Locations > Page 9952 Cruise Control Vacuum Reservoir: Service and Repair REMOVAL 1. Release hood latch and open hood. 2. Disconnect the negative battery cable. 3. Disconnect the vacuum line to the battery trayl vacuum reservoir. 4. Remove battery tray/vacuum reservoir, refer to the Battery section for more information. INSTALLATION 1. Install battery tray/vacuum reservoir, refer to the Battery section for more information. 2. Connect vacuum line that leads to the battery tray/vacuum reservoir. 3. Connect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Speed Control Switches Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 9957 Cruise Control Switch: Diagrams Left Speed Control Switch Right Speed Control Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 9958 Cruise Control Switch: Service Precautions WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO THE RESTRAINT SYSTEMS SECTION FOR MORE INFORMATION. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 9959 Cruise Control Switch: Description and Operation There are two separate switch pods that operate the speed control system and are located on the steering wheel. The speed control system has five separate resistive switches that provide a single multiplexed (MUX) voltage inputs to the PCM.The switch names are: ON, OFF, SET, COAST, RESUME, ACCEL, TAPUP COAST, and CANCEL. Based on conditions when the buttons are pushed (and released), the five voltages ranges provided to the PCM result in the following functions: ON, OFF, SET, COAST, RESUME, ACCEL, TAP-UP TAP-DOWN, COAST, and CANCEL. Refer to the Speed Control Section for more information Also the PCM receives an input from the brake switch to sense whether the brake pedal has been depressed. When the PCM receives the brake depressed input, it turns OFF power to the speed control servo and disengages speed control. Also the power to the servo is supplied through the brake switch, which opens the circuit when the brake pedal is depressed. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 9960 Cruise Control Switch: Service and Repair REMOVAL The speed control switches are mounted in the steering wheel and wired through the clock spring device under the airbag module. WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO THE RESTRAINT SYSTEMS SECTION FOR MORE INFORMATION. 1. Remove the negative battery cable. 2. Turn OFF ignition. 3. Remove the air bag, refer to the restraint section for more information. 4. Remove the screw from bottom of the switch. 5. Remove switch from steering wheel. 6. Disconnect two-way electrical connector. 7. Repeat for the other switch. INSTALLATION The speed control switches are mounted in the steering wheel and wired through the clock spring device under the airbag module. WARNING: IF REMOVAL OF AIRBAG MODULE IS NECESSARY, REFER TO THE RESTRAINT SYSTEMS SECTION FOR MORE INFORMATION. 1. Connect two-way electrical connector. 2. Install switch. 3. Install screw for the switch. 4. Repeat for the other switch. 5. Install the air bag, refer to the restraint section for more information. 6. Install the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component Information > Application and ID Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component Information > Application and ID > Page 9965 Air Bag Deactivation Indicator: Description and Operation PASSENGER AIRBAG DISABLED INDICATOR Passenger Airbag Disabled (PAD) Indicator Vehicles equipped with the Occupant Classification System (OCS) include a Passenger Air bag Disabled (PAD) indicator which is located in the instrument panel center stack, above the radio. The PAD indicator is present only in vehicles equipped with the OCS. The PAD indicator consists of a molded plastic housing with an integral connector at the back. An amber Light Emitting Diode (LED) behind the lens causes the "PASS AIR BAG OFF" text and icon to appear silhouetted against an amber field through the translucent lens when the indicator is illuminated from behind by the LED. The PAD indicator is available for separate service replacement. In vehicles equipped with the Occupant Classification System (OCS), the Passenger Airbag Disabled (PAD) indicator gives an indication when the passenger airbag and seat belt tensioner deployment circuits are disabled by the Occupant Restraint Controller (ORC). The PAD indicator is controlled by a transistor within the ORC through a hard wired output based upon ORC programming and electronic occupant classification messages received by the ORC over the Programmable Communications Interface (PCI) data bus from the Occupant Classification Module (OCM). The PAD indicator Light Emitting Diode (LED) is completely controlled by the ORC. The LED receives a battery current input on the fused ignition switch output (RUN/START) circuit. Therefore, the LED will always be OFF when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the ORC transistor. The ORC will turn on the PAD indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the PAD indicator is illuminated for about six seconds. - Child Seat Detected Occupant Classification Message - Each time the ORC receives a message from the OCM indicating a child seat has been detected in the passenger front seat, the passenger airbag and seat belt tensioner deployment circuits are deactivated and the PAD indicator will be illuminated. The indicator remains illuminated until the ORC receives an occupant classification message indicating that: The passenger front seat is empty. - The seat is occupied by a load equal to or greater than a fifth percentile female. - OR, Until the ignition switch is turned to the OFF position, whichever of these three occurs first. - Load Less Than Fifth Percentile Female Occupant Classification Message - Each time the ORC receives a message from the OCM indicating that a load less than a fifth percentile female has been detected in the passenger front seat, the passenger airbag and seat belt tensioner deployment circuits are deactivated and the PAD indicator will be illuminated. The indicator remains illuminated until: The ORC receives an occupant classification message indicating that the passenger front seat is empty. - The seat is occupied by a load equal to or greater than a fifth percentile female. - OR, until the ignition switch is turned to the OFF position, whichever of these three occurs first. - Load Undetermined Occupant Classification Message - Each time the ORC receives a message from the OCM indicating that a load cannot be determined in the passenger front seat, the passenger airbag and seat belt tensioner deployment circuits are deactivated and the PAD indicator will be illuminated. The indicator remains illuminated until: The ORC receives an occupant classification message indicating that the passenger front seat is empty. - The seat is occupied by a load equal to or greater than a fifth percentile female. - OR, until the ignition switch is turned to the OFF position, whichever of these three occurs first. - Communication Error - If the ORC receives invalid occupant classification messages or no messages from the OCM, the PAD indicator is illuminated. The indicator remains illuminated until: The ORC receives an occupant classification message indicating that the passenger front seat is empty. - The seat is occupied by a load equal to or greater than a fifth percentile female. - OR, until the ignition switch is turned to the OFF position, whichever of these three occurs first. The ORC continually monitors the occupant classification messages from the OCM to decide whether the passenger airbag and seat belt tensioner deployment circuits should be activated or deactivated. Note that there may be several seconds of delay between changes in the detected occupant status and PAD indications. This is a programmed feature of the OCM used to prevent a flashing indicator condition resulting from the normal shifting of occupant weight on the passenger seat cushion. The ORC then provides the proper control output to turn the PAD indicator ON or OFF. The ORC will store a Diagnostic Trouble Code (DTC) for any malfunction it detects. For proper diagnosis of the OCM, the ORC, the PCI data bus, or the electronic message inputs to the ORC that control the PAD indicator, use a scan tool and the appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Bag Deactivation Indicator > Component Information > Application and ID > Page 9966 Air Bag Deactivation Indicator: Service and Repair PASSENGER AIRBAG DISABLED INDICATOR REMOVAL 1. Open hood. 2. Disconnect and isolate the battery negative cable. WARNING: WAIT TWO MINUTES FOR THE AIRBAG SYSTEM RESERVE CAPACITOR TO DISCHARGE BEFORE BEGINNING ANY AIRBAG SYSTEM OR COMPONENT SERVICE. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, PERSONAL INJURY OR DEATH. 3. Remove instrument panel center bezel. 4. From the back of the center bezel, depress the two latches toward the indicator housing and push the indicator out through the face of the center bezel. INSTALLATION 1. From the face of the instrument panel center bezel, align the Passenger Airbag Disabled (PAD) indicator housing with the mounting hole. 2. Firmly push the indicator into the center bezel until the two latches are fully engaged on the back of the cap and are snapped in. 3. Install the instrument panel center bezel. WARNING: - DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. - FOLLOWING SUCCESSFUL COMPLETION OF THE AIRBAG SYSTEM TEST PROCEDURE, THE OCCUPANT CLASSIFICATION SYSTEM VERIFICATION TEST MUST BE DONE USING A SCAN TOOL AND THE APPROPRIATE DIAGNOSTIC INFORMATION. 4. Close hood. 5. Verify system and vehicle operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Service Precautions Audible Warning Device: Service Precautions WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT, PERSONAL INJURY, OR DEATH. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Service Precautions > Page 9970 Audible Warning Device: Description and Operation The BCM monitors the door/liftgate ajar switches, multifunction switches, headlight switch, ignition switch, PCI bus, and the diagnostic tool to perform various chime operations. The BCM uses a low-side driver to control the chime located in the cluster. The chime system provides the Driver with warning chimes for: - Seat belt - Exterior lights on - Key-in Ignition - Key-in Accessory - Engine temperature critical - Low washer fluid - Turn signals on - Dome light on - Low oil pressure - Any warning lamp announcement - High-speed warning Gulf Coast Countries (GCC) only The output sound intensity of the chime is approximately 72 decibels. CHIME PRIORITY The following list indicates the priority of the chime when more than one chime is active at the same time: - Seat belt warning - High-speed warning Gulf Coast Countries (GCC) only - Turn signal on - Chime request - Warning lamp announcement The cluster is responsible to set priority on all warning lamp announcement chimes. CHIME ON CONDITIONS The following is a list of the chime warnings and when they will sound. Driver's Seat: Sounds for approximately 6 ± 2 belt Unbuckled: seconds when the ignition is turned on driver's seat belt is not buckled, as a reminder to the driver to buckle the seat belt. Exterior Lights On:Ignition is in the lock position, the driver door is ajar, and the headlight switch is left in any position, other than auto or off.The chime will sound as a warning to the driver until one of the above conditions is removed or until the battery protection time of 3 minutes has expired. Key-In Ignition: Ignition is in the lock position, driver door is ajar and the key is in the ignition. The chime will sound until one of the above conditions is removed or until the battery protection time of 15 minutes has expired. Turn Signal On: When the BCM detects a turn signal input continuously for 1.0 mile/0.6 km and the vehicle speed is greater than 15 mph/24 kph, the chime will sound until the specific turn signal is cancelled. Dome Lights On: Ignition is in the lock position, driver door ajar, and the dome light switch is left in the on position. The chime will sound until one of the above conditions is removed or until the battery protection time of 15 minutes has expired. Low Oil Pressure: The chime will sound when the engine is operating and the oil pressure drops below 4 psi/27.5 kPa. Engine Temperature Critical: The chime will sound when the engine is operating and the coolant temperature exceeds 252° F/122° C or 234° C/112° C(diesel). The chime is continuous at 257° F/ 125° C and will chime for 4 minutes and stop if the temperature drops below 255° F/123° C. Low Washer The chime will sound when the Fluid washer fluid drops below a specific level. Warning Lamp Announcement: A chime will sound to alert the driver to scan the instrument panel and overhead console to see which warning lamp is illuminated. The door/liftgate ajar warning lamp will appear without a chime if the vehicle is running and a door or the liftgate is opened. A chime will sound if the door or liftgate is still open and the vehicle speed is greater than 4 mph/6 kph. High-speed warning Gulf Coast Countries (GCC) only The chime will sound, acting as a warning to the driver that the vehicle speed has exceed 75 mph ± 2/120 kph ± 3. WARNING LAMP ANNOUNCEMENT Low Fuel Lamp: The cluster will request a single chime after the indicator is illuminated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Service Precautions > Page 9971 Volt Lamp: The cluster will request a single chime after the indicator is illuminated. Oil Pressure Lamp: The cluster will request a single chime after illuminating the indicator above 450 rpm vehicle operation. Liftgate Ajar Lamp: The BCM determines when to chime for liftgate ajar. Fasten Seat Belt Lamp: The MIC will request a single chime from the BCM when the ignition is turned to the unlock/ run/start positions if the driver seat belt is not buckled and 2 seconds after seatbelt warning chime ends. Check Engine Lamp: The cluster will request a single chime after the indicator is illuminated. Low Washer Fluid Lamp: The cluster will request a single chime after the indicator is illuminated. Engine Temperature Lamp: The cluster will request a single chime when the indicator is first illuminated at 252° F/122° C. OTHER CHIME ON CONDITIONS Programming of an Additional Key Fob: Asingle cluster chime will sound, which signals that the program mode has been initiated. Programming for Rolling Door Locks: When the programming has been completed, a single tone from the chime system, will occur. PARK ASSIST SYSTEM The Park Assist System is an electronic parking aid that alerts the driver to obstacles which are located immediately behind the vehicle. Objects are sensed using ultrasonic sound waves. When an object is detected, the system will give the driver visual and audible warnings. The system is customer programmable through the Electronic Vehicle Information Center (EVIC) but will be enabled from the factory as a default. The major components of the park assist system are: - Park Assist Module - supplies voltage to the object detection sensors and park assist display. It triggers the sensors, analyzes the echo delay times and calculates obstacle distances. It sends display information to the park assist display, performs system diagnostics, and communicates via the Programmable Communication Interface (PCI) date bus network. - Park Assist Sensors - there are four sensors located in the rear bumper that generate ultrasonic pulses when triggered by the park assist module. The sensors signal the park assist module when reflected ultrasonic pulses are received. - Park Assist Display - there are sixteen Light Emitting Diode (LED) indicators which provide indication of relative distance to obstacles. When the system is engaged and no obstacles are detected, the two outermost yellow LED's are lit at reduced brightness to show the system is working. As the distance to a detected obstacle decreases, more yellow LED's towards the center of the display illuminate. For diagnosis and testing of the park assist system, use a scan tool and the appropriate body diagnostic information. The Park Assist System display activates an audible tone that changes from intermittent to continuous as the final two Light Emitting Diodes (LED's) are illuminated on one side or both sides of the display. The system detection length from the rear of the vehicle is 0.3 meters to 1.5 meters. This area extends around the rear side of the vehicle. The system detection height from the ground is 0.2 meters to about 1.5 meters. The radio mutes when the system activates its audible tone. When the driver selects Reverse the system scans for objects behind the vehicle using four sensors located in the rear bumper. A warning display above the rear window provides both visible and audible warnings indicating the range of the object. The system is active only when the transmission gear selector is in reverse for vehicle speeds less than 16 Km/h (10 mph). If the vehicle's Parking/Emergency Brake is applied, the system is deactivated. The display contains two sets of yellow and red Light Emitting Diode's (LED's) that the driver can see as they look over their shoulder while backing up. Each side of the vehicle has its own warning LED's. The system provides a visual warning by illuminating one or more yellow LED's as the vehicle gets closer to the object. As the vehicle continues to approach the object, one red LED is illuminated and the system emits a series of short beeps. The tone will remain constant and both red LED's are illuminated once the vehicle is within 12 inches (30.5 cm) of the object. The system can be turned ON or OFF through the Electronic Vehicle Information Center (EVIC) when the vehicle is in PARK. If the park assist system is turned OFF, a single chime will sound and the EVIC will display the following message "REAR PARK ASSIST OFF", when the vehicle is in reverse. - Ensure that the rear bumper is free of dirt and debris to keep the system operating properly. - Jackhammers, large trucks, and other vibrations could affect the performance of the system. - Ensure that the parking brake is not applied. If "Service Park Assist System" appears in the EVIC after making sure the rear bumper is clean, proceed to diagnose the system using a scan tool and the appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Service Precautions > Page 9972 Audible Warning Device: Testing and Inspection NO TONE WHEN IGNITION SWITCH IS TURNED ON AND DRIVERS SEAT BELT IS NOT BUCKLED. 1. Using a DRB III (R) scan tool, actuate chime (BCM actuates). 2. Using a voltmeter, check for voltage: a. BCM has two battery feeds at pin 1 and pin 5 of the 6-way connector. b. Pin 5 of the (BX2) 32 way connector of the BCM for ignition feed. c. Check voltage (PX2) connector, pin 34 for 12v d. If voltage OK, go to step Step 3 e. If NO voltage repair as necessary. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. 3. Check drivers seat belt buckle switch input (from Occupant Restraint Controller (ORC) for a closed circuit when not buckled. If input not seen, look for open in wiring or switch. The switch is grounded when belt is not buckled. 4. Verify Programmable Communication Interface (PCI) data bus communication between ORC and BCM. NO FASTEN SEAT BELT LAMP WHEN IGNITION SWITCH IS TURNED ON. 1. Check for burned out lamp. 2. Using a voltmeter check for voltage at the cluster connector: a. Pin 2 of the mechanical instrument cluster for battery feed. b. Pin 11 of the mechanical instrument cluster for ignition voltage. 3. Repair as necessary. FASTEN SEAT BELT LAMP OR TONE CONTINUES FOR MORE THAN 10 SECONDS AFTER SEAT BELTS ARE FASTENED AND DRIVER'S DOOR IS CLOSED. Refer to the proper Body Diagnostic Procedures manual. NO TONE WHEN PARK OR HEADLAMPS ARE ON AND DRIVER'S DOOR IS OPEN. Make sure ignition is in lock position with the key removed. 1. Check the BCM DTC's and BCM sensors to verify the door is open. Repair as necessary. 2. Actuate Chime (BCM actuates). 3. Inspect BCM connectors and wires for proper connection. 4. Measure with a voltmeter the voltage (12v) on BCM connector (PX2) pin 34 with harness connected. 5. Check BCM sensors to verify headlamp switch position. For additional information regarding Trouble Code Diagnostic Charts for this system, please refer to Body Control Module testing. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation Brake Warning Indicator: Description and Operation ABS AND BRAKE WARNING INDICATORS The amber ABS warning indicator is located in the instrument cluster. It is used to inform the driver that the antilock function has been turned off. The ABS warning indicator is controlled by the CAB/ABM. The CAB/ABM controls the lamp with a command over the PCI bus. The ABS Warning Indicator will remain lit during every key cycle until a circuit or component fault is repaired and the CAB/ABM no longer detects the fault. After repair of a sensor signal fault or a pump motor fault, the CAB/ABM must sense all four wheels at 25 km/h (15 mph) before it will extinguish the ABS and TCS Indicator. The Instrument Cluster will illuminate the ABS Warning Indicator if it loses communication with the CAB/ABM. The red BRAKE warning indicator is also located in the instrument cluster. It can be activated in several ways. Application of the parking brake or a low fluid signal from the fluid level switch located in the master cylinder reservoir will cause the indicator to come on. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9980 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9981 Figure 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9982 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9983 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9984 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9985 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9986 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9987 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9988 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9989 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9990 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9991 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9992 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9993 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9994 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9995 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9996 Cigarette Lighter: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and an Electrostatic Discharge Symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9997 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9998 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9999 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10000 Front Cigar Lighter Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10001 Cigarette Lighter: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-41-2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10002 8w-41-3 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10003 8w-41-4 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation Compass: Description and Operation The Compass Mini-Trip Computer (CMTC) module is located in the overhead console. The CMTC consists of a electronic control module with a vacuum fluorescent display (VFD) and function switches. The CMTC consists of a electronic module that displays compass, trip computer, and temperature features. Actuating the STEP push button will cause the CMTC to change mode of operation when the ignition is ON. Example: - Average miles per gallon (ECO) - Distance to empty (DTE) - Instant miles per gallon (ECO) - Trip odometer (ODO) - Elapsed time (ET) - Blank Actuating the C/T push button will cause the CMTC to change to the Compass/Temperature display. The Compass Mini-Trip Computer (CMTC) module in the overhead console has buttons used to select various functions. The CMTC selector buttons will not operate until the ignition is in the RUN position. When the ignition switch is first turned to the RUN position the CMTC display; - Blanks momentarily - All segments of the VFD will light for one second - Blanks momentarily - Returns to the last mode setting selected before the ignition was last switched OFF. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation > Page 10007 Compass: Testing and Inspection Any diagnosis of the compass mini-trip computer should begin with the use of the DRB III(R) diagnostic tool. For information on the use of the DRB III(R), refer to the appropriate Diagnostic Procedures information. Compass Mini-Trip Computer (CMTC) data is obtained from the Body Control Module (BCM) on the Programmable Communications Interface (PCI) Data Bus circuit. The CMTC will display dashes (- -) for any of the screens it did not receive the bus messages. The label corresponding to the missing information will be lit. If no CMTC data is displayed, check the PCI Data Bus circuit communications and the BCM. If the dimming level is improper check the PCI Data Bus circuit. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Description and Operation > Page 10008 Compass: Adjustments Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance setting may need to be changed. To set the compass variance: Variance Settings 1. Using the Variance Settings map, find your geographic location and note the zone number. 2. Turn the ignition switch to the On position. If the compass/thermometer data is not currently being displayed, momentarily depress and release the C/T push button to reach the compass/thermometer display. 3. On Electronic Vehicle Information Center (EVIC) and Compass Mini-Trip Computer (CMTC) equipped vehicles depress the Reset push button and hold the button down until "VAR = XX" appears in the display. This takes about five seconds. On Compass Temperature Module (CT) equipped vehicles depress the C/T push button and US/M push button down until "VAR = XX" appears in the display. This takes about five seconds. 4. Release the push button(s). "VAR =XX " will remain in the display. "XX" equals the current variance zone setting. 5. On Electronic Vehicle Information Center (EVIC) and Compass Mini-Trip Computer (CMTC) equipped vehicles momentarily depress and release the STEP button to step through the zone numbers, until the zone number for your geographic location appears in the display. On Compass Temperature Module (CT) equipped vehicles depress the US/M push button to step through the zone numbers, until the zone number for your geographic location appears in the display. 6. On Electronic Vehicle Information Center (EVIC) and Compass Mini-Trip Computer (CMTC) equipped vehicles momentarily depress and release the RESET push button to enter the displayed zone number into the EVIC/CMTC module memory. On Compass Temperature Module (CT) equipped vehicles depress the C/T push button to enter the displayed zone number into the electronic module memory. 7. Confirm that the correct directions are now indicated by the compass. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration Compass: Service and Repair Compass Calibration CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the compass. Do not use magnetic tools when servicing the overhead console. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism the vehicle may acquire during normal use. If the compass readings appear to be erratic or out of calibration, perform the following calibration procedure. Also, new service replacement Electronic Modules (EVIC, CMTC, CT) must have their compass calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. NOTE: Whenever the compass is calibrated manually, the variance number must also be reset. Calibrate the compass manually as follows: 1. Turn the ignition switch to the On position. If the compass/thermometer data is not currently being displayed, momentarily depress and release the C/T push button to reach the compass/thermometer display. 2. On Electronic Vehicle Information Center (EVIC) and Compass Mini-Trip Computer (CMTC) equipped vehicles depress the Reset push button and hold the button until "CAL" appears in the display. This takes about ten seconds, and appears about five seconds after "VAR = XX" is displayed. On Compass Temperature Module (CT) equipped vehicles depress the C/T push button and US/M push button down until "CAL" appears in the display. This takes about ten seconds, and appears about five seconds after "VAR = XX" is displayed. 3. Release the push button(s). 4. Drive the vehicle on a level surface, away from large metal objects and power lines, through three or more complete circles at between five and eight kilometers-per-hour (three and five miles-per-hour) for a minimum of 48 seconds. The "CAL" message will disappear from the display to indicate that the compass is now calibrated. NOTE: If the "CAL" message remains in the display, either there is excessive magnetism near the compass, or the unit is faulty. Repeat the calibration procedure one more time. - If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the calibration procedure in another location. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration > Page 10011 Compass: Service and Repair Compass Demagnetizing A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the overhead console forward mounting screw and the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel and the overhead console forward mounting screw, proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. Degaussing Tool 6029 2. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 3. Slowly approach the head of the overhead console forward mounting screw with the degaussing tool connected. 4. Contact the head of the screw with the plastic coated tip of the degaussing tool for about two seconds. 5. With the degaussing tool still energized, slowly back it away from the screw. When the tip of the tool is at least 61 centimeters (2 feet) from the screw head, disconnect the tool. Roof Demagnetizing Pattern 6. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 7. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 8. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 9. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration > Page 10012 Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 10. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 11. Calibrate the compass and adjust the compass variance. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration > Page 10013 Compass: Service and Repair Overhead Console REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console retaining screw, located in the front of console. 3. Grasp the sides of the overhead console and pull straight down evenly to disengage the two snap clips at the rear of the unit. 4. Lower the overhead console far enough to access the wire harness connectors. 5. Disconnect the EVIC, CMTC or CT electronic module and the reading/courtesy lamps electrical connector. 6. Remove the overhead console from the vehicle. INSTALLATION 1. Position the overhead console in the vehicle. 2. Connect the EVIC, CMTC or CT electronic module and the reading/courtesy lamps electrical connector. 3. Using your fingertips, grasp the sides of the overhead console and push straight up evenly to engage the two snap clips at the rear of the unit. CAUTION: DO NOT PRESS ON THE SUNGLASS STORAGE BIN DOOR. DAMAGE TO THE DOOR MAY RESULT. 4. Install the overhead console retaining screw, located in the front of console. Torque the screw to 1.2 N.m (10 in. lbs.). 5. Connect the remote negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Compass Calibration > Page 10014 Compass: Service and Repair Compass/Mini-Trip Computer REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove overhead console. 3. Remove the screws holding Compass Mini-Trip Computer (CMTC) module in the overhead console. 4. Remove CMTC module from the console assembly. INSTALLATION 1. Position the compass mini-trip computer (CMTC) module in the overhead console. 2. Install the ten screws holding the CMTC module in the overhead console. 3. Install the overhead console. 4. Connect the battery negative cable. NOTE: If a new CMTC module has been installed, the compass will have to be calibrated and the variance set. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Service and Repair > Page 10015 Degaussing Tool #6029 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 10021 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 10022 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Page 10023 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation Door/Trunk Ajar Indicator/Lamp: Description and Operation The door ajar and liftgate ajar states are used as inputs for the Body Control Module (BCM). The BCM uses these inputs to determine exactly what position the doors and liftgate are in. The DRBIII(R) will display the state of the door ajar and the liftgate ajar switches in Inputs/Outputs. It's important to note, that when any door, or the liftgate is closed, the switch state on the DRBIII(R) will show OPEN. When any door, or the liftgate is open the switch state on the DRBIII(R) will show CLOSED. During diagnosis, if a door or the liftgate is closed and the DRBIII(R) displays the switch state as CLOSED, it indicates a shorted ajar circuit. If the door or the liftgate is open and the DRBIII(R) displays the switch state as OPEN, it indicates an open ajar circuit. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations Door Switch: Locations Right B Pillar Left B Pillar Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 10030 Driver Door Passenger Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 10031 Right Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 10032 Liftgate Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 10033 Door Switch: Diagrams Hood Ajar Switch (Export) Left Front Ajar Switch (Base) Left Front Door Lock Motor/Ajar Switch (Except Base) Right Front Door Switch Ajar Switch (Base) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 10034 Right Front Door Lock Motor/Ajar Switch (Except Base) Right Sliding Door Lock Motor/Ajar Switch (Manual Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10040 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10041 Figure 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10042 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10043 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10044 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10045 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10046 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10047 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10048 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10049 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10050 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10051 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10052 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10053 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10054 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10055 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10056 Driver/Vehicle Information Display: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and an Electrostatic Discharge Symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10057 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10058 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10059 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 10060 Message Center (Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console Driver/Vehicle Information Display: Description and Operation Overhead Console OVERHEAD CONSOLE Three overhead consoles options are available on this vehicle. These options are: - The Electronic Vehicle Information Center (EVIC) - The Compass Mini-Trip Computer (CMTC) All consoles are equipped with two reading/courtesy lamps and if the vehicle is equipped with a power liftgate or power sliding door(s) the overhead console will also include switches for these features. The overhead console is mounted with one screw and two snap clips to a molded plastic retainer bracket located above the headliner. COMPASS All overhead consoles include compass information. While in the compass/temperature mode, the compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may be necessary is to drive the vehicle in three complete circles at 5 to 8 kilometers-per-hour (3 to 5 miles-per-hour), on level ground, for a minimum of forty-eight seconds. This will reorient the compass unit to its vehicle. The compass unit will also compensate for magnetism the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. The use of magnetic tools on the fasteners that hold the overhead console assembly to the roof header can also affect compass operation. If the compass operation is erratic and roof magnetization is suspected, refer to Compass Demagnetizing. See: Compass/Service and Repair/Compass Demagnetizing TEMPERATURE All overhead consoles include temperature information. The temperature displays the outside ambient temperature in whole degrees. The temperature display can be toggled from Fahrenheit to Celsius by selecting the desired U.S./Metric option from the customer programmable features. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the temperature display several minutes to respond to a major temperature change, such as driving out of a heated garage into winter temperatures. When the ignition switch is turned to the Off position, the last displayed temperature reading stays in the electronic control modules (CMTC, EVIC) memory. When the ignition switch is turned to the On position again, the electronic module will display the memory temperature for one minute; then update the display to the current average temperature reading within five minutes. The temperature function is supported by an ambient temperature sensor. The sensor is mounted near the front and center of the vehicle, and is hard wired to the Powertrain Control Module (PCM). The PCM sends temperature status messages to the module over the Programmable Communication Interface (PCI) data bus circuit. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 10063 Driver/Vehicle Information Display: Description and Operation Electronic Vehicle Information Center Description The Electronic Vehicle Information Center (EVIC) is located in the overhead console. The EVIC features a large Vacuum Fluorescent Display (VFD) screen for displaying information, and back-lit push button switches labeled C/T (compass/thermometer), RESET, STEP, and MENU. The EVIC module contains a central processing unit and interfaces with other electronic modules in the vehicle over the Programmable Communications Interface (PCI) data bus circuit. The EVIC "Menu" push button provides the vehicle operator with a user interface, which allows the selection of several optional customer programmable electronic features to suit individual preferences. If the vehicle is equipped with the optional universal transmitter transceiver, the EVIC will also display messages and an icon indicating when the universal transmitter transceiver is being trained, which of the three transmitter buttons is transmitting, and when the transceiver is cleared. Data input for all EVIC functions, including VFD dimming level, is received through the PCI data bus circuit. The EVIC module uses its internal programming and all of its data inputs to calculate and display the requested data. If the data displayed is incorrect, perform the SELF - DIAGNOSTIC TEST. If these tests prove inconclusive, the use of a DRBIII(R) scan tool and the proper diagnostic procedures information are recommended for further testing of the EVIC module and the PCI data bus circuit. The EVIC module cannot be repaired, and is available for service only as a unit. This unit includes the plastic module and display lens. If any of these components is faulty or damaged, the complete EVIC module must be replaced. The Electronic Vehicle Information Center (EVIC) uses both non-switched and ignition switched sources of battery current so that some of its features remain operational at any time, while others may only operate with the ignition switch in the On position. When the ignition switch is turned to the On position, the EVIC module Vacuum Fluorescent Display (VFD) will return to the last function being displayed before the ignition was turned to the Off position. The compass/thermometer display is the normal EVIC display. With the ignition switch in the On position, momentarily depressing and releasing the C/T (compass/thermometer) push button switch will cause the EVIC to return to the compass/thermometer/trip computer display mode from any other mode. While in the compass/thermometer/trip computer display mode, momentarily depressing and releasing the Step push button will step through the available trip computer display options. The EVIC trip computer features several functions that can be reset. The functions that can be reset are: - Average fuel economy - Trip odometer - Elapsed time With the ignition switch in the On position and with one of the functions of the trip computer that can be reset currently displayed, depressing the Reset push button twice within four seconds will perform a global reset, and all of the trip computer information that can be reset will be reset to zero. With the ignition switch in the On position and the function that is to be reset currently displayed, momentarily depressing and holding the Reset push button for one second will perform a local reset, and only the value of the displayed function will be reset to zero. A global or local reset will only occur if the function currently displayed is a function that can be reset. The distance to service function can also be reset using the local reset method, but it will reset back to the Service Interval distance that is set in the EVIC programmable features mode. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 10064 Driver/Vehicle Information Display: Description and Operation Electronic Vehicle Information Center Operation COMPASS/TEMPERATURE MODULE, COMPASS/MINI-TRIP COMPUTER or ELECTRONIC VEHICLE INFORMATION CENTER The Compass/Temperature Module (CT), Compass/Mini-Trip Computer (CMTC) or Electronic Vehicle Information Center (EVIC) is located in the overhead console. The CT provides the vehicle operator with only outdoor temperature and the compass heading. The CMTC or EVIC supplements the standard vehicle instrumentation. The CMTC and EVIC use a vacuum fluorescent (VF) display to supply the vehicle operator with a compass heading, outdoor temperature, average fuel economy, distance to empty, trip odometer, elapsed ignition on time, distance to service, warning messages, and service messages. The difference between a CMTC and an EVIC is that only the EVIC provides additional memory, feature programming, and warning messages. The EVIC is capable of displaying warning messages and memory system messages when the vehicle is equipped with memory systems. The EVIC also provides the interface to enable and disable vehicle programmable features when the vehicle is equipped with certain features. If equipped, the EVIC is also available with an integrated Universal Garage Door Opener (UGDO) known as HomeLink(R). The EVIC may also be equipped with up to 4 power door switches: ON/ OFF, Left Sliding Door, Right Sliding Door, and Liftgate. The CT function buttons are labeled C/T and US/M. The CMTC function buttons are labeled US/M, C/T, RESET, and STEP. The EVIC function buttons are labeled C/T, RESET, STEP, and MENU. The three UGDO buttons are labeled with dots to indicate the channel number. The BCM supplies most of the information displayed by the CMTC/EVIC. Display information, except for the internal compass function, is received over the PCI bus. The FCM supplies the ambient temperature sensor information via the PCI bus. The CMTC/EVIC sends and receives data over the PCI bus, communicating with the BCM, PCM, FCM, and the Instrument Cluster. Tire Pressure Monitoring System information is received from the SKREEM via PCI bus information. The tire pressure sensors are mounted to the vehicle wheels. For complete information, refer to the Tire Pressure Monitoring System. VEHICLE INFORMATION DISPLAY The CMTC/EVIC provides the following functions: - Compass direction - Outside temperature - Elapsed ignition on time - Distance to empty - Average fuel economy - Trip odometer - Distance to service The EVIC will also display the following driver alert messages: - TURN SIGNAL ON (with vehicle graphic) - PERFORM SERVICE - DOOR OPEN (individual or multiple doors, with graphic) - LOW TIRE PRESSURE (when equipped) - ADJUSTABLE PEDAL DISABLED CRUISE ENGAGED (when equipped) - ADJUSTABLE PEDAL DISABLED VEHICLE IN REVERSE (when equipped) An audible chime or chimes will accompany any displayed warning messages. Chime requests with an OPEN message are dependent upon vehicle speed. The CT/CMTC/EVIC will not display information for any of the screens for which it did not receive the proper PCI bus data. Refer to the symptom list in the Overhead Console section for problems related to the CT/CMTC/EVIC. The CMTC/EVIC receives the following messages from the Body Control Module (BCM): - Verification of US/Metric status - VF display dimming brightness and exterior lamp status - Elapsed Ignition On Time data - Average Fuel Economy - Distance to Empty - Distance to service - Driver warning messages The CT/CMTC/EVIC receives the following messages from the Front Control Module (FCM): - Outside Temperature The CMTC/EVIC receives the following messages from the Powertrain Control Module (PCM): Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 10065 - Trip Odometer data - Vehicle Speed The EVIC receives the following messages from the Adjustable Pedal System Module (APS): - APS status warnings The CT/CMTC/EVIC receives the following messages from the Sentry Key Remote Electronic Entry Module (SKREEM): - Tire Pressure information The CMTC/EVIC transmits the following messages to the BCM: - Status Request: Beep, Reset, US/M Toggle - Current Display STEP BUTTON The STEP Button can be used in one of the following three ways: 1. To sequentially select one of seven displays or blank display in the following order: - Average Fuel Economy - Distance to Empty - Trip Odometer - Time Elapsed - Distance to Service Message - Off (Blank) 2. To set the magnetic variance zone when VARIANCE = X (X = 1 - 15) is indicated in the VF Display. 3. To select the displayed programmable feature setting. (When equipped.) MENU BUTTON (EVIC only) For complete information of the programmable features and memory messages. Use the MENU button to sequentially step the EVIC through the programmable features. MENU BUTTON (EVIC only) For complete information of the programmable features and memory messages.Use the MENU button to sequentially step the EVIC through the programmable features. RESET BUTTON The RESET Button has two different functions: 1. To clear the trip functions that may be reset 2. To enter and exit the diagnostic mode Pressing the RESET button once will clear the trip function that is currently being displayed (except Distance to Service) and the CMTC/EVIC will send a PCI bus beep request to the BCM. If the RESET button is pressed again within 3 seconds, the CMTC/EVIC will reset ALL of the trip functions and an additional beep request is sent to the BCM. The trip functions that may be reset are: - Average Fuel Economy - Trip Odometer - Elapsed Time A reset will only occur if one of the trip functions that may be reset is currently being displayed. Pressing the RESET button for more than three (3) seconds resets the Distance to Service function while the Distance to Service message is being displayed. The CMTC/EVIC module will send a beep request to the BCM. Simultaneously pressing the RESET button and the STEP button while turning the ignition from Off to On will enter the CMTC/EVIC into the self-diagnostic mode. COMPASS/TEMPERATURE (C/T) BUTTON Actuating the Compass/Temperature Button (C/T) will cause the CMTC/EVIC to display the compass and temperature information. This function will operate from another traveler display or from the programmable feature mode. TRAVELER DISPLAY FUNCTIONS Using the STEP button will change the CMTC/ EVIC between modes of operation and display the appropriate information according to data received from the PCI Bus. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 10066 COMPASS/TEMPERATURE The CMTC/EVIC simultaneously displays the compass reading and the outside temperature. Outside temperature information is received via the PCI bus from the FCM. The CMTC/EVIC module internally senses and calculates the compass direction. COMPASS OPERATION - ALL Upon ignition on, if the calibration information stored in the CMTC memory is within the normal range, the CMTC will perform in slow Auto-Cal mode. In slow Auto-Cal mode, the CMTC continuously compensates for the slowly changing magnetic field of the vehicle. The compass module detects changes in the vehicle magnetism and makes appropriate internal corrections to ensure proper displayed direction. However, if the calibration information stored in the CMTC memory is not within the normal range at ignition on, the CMTC will enter fast Auto-Cal. CAL is displayed along with the temperature. Auto activation of the fast Auto-Cal mode will also occur when the CMTC is subjected to high magnetic field strength levels, which cause all compass readings to be erroneous for a continuous period of five (5) minutes. During fast Auto-Cal, CAL will be displayed along with the temperature. Fast Auto-Cal can also be performed manually, by pressing and holding the RESET button for 10 seconds during the Compass/Temperature display mode. SETTING MAGNETIC ZONE VARIANCE Variance is the difference between magnetic North and geographic North. For proper compass function, the correct variance zone must be set. Refer to the Zone Variance map for the correct zone. Follow these steps to check or change the variance zone: CMTC/EVIC: - The ignition switch must be in the On position and the CMTC/EVIC display must not be blank. - If the compass/temperature data is not currently being displayed, momentarily press and release the C/T button to display compass/temp information. - Press and hold the RESET button (approximately 5 seconds) until VARIANCE = XX is displayed. The CMTC/EVIC will display the variance zone stored in memory and the word VARIANCE. - Use the RESET button to select the proper variance zone number, 1 through 15. - After selecting the proper zone number, momentarily press and release the RESET button. The variance zone is then stored in the memory and the CMTC/EVIC returns to normal operation. CT: - The ignition switch must be in the On position and the C/T display must not be blank. Press and hold the C/T and US/M buttons (approximately 5 seconds) until VARIANCE = XX is displayed. The C/T will display the variance zone stored in memory and the word VARIANCE. - Use the US/M button to select the proper variance zone number, 1 through 15. - After selecting the proper zone number, momentarily press and release the C/T button. The variance zone is then stored in the memory and the C/T returns to normal operation. COMPASS CALIBRATION The compass module has 2 types of auto calibration; slow-cal and fast-cal. Slow-cal ensures that during normal vehicle operation th0e compass performs auto-calibration functions to keep the compass sensors in their proper operating range. Whenever the ignition is On and the CT/CMTC/ EVIC receives PCI bus data indicating that engine RPM is greater than zero, auto-calibration is performed continuously. If the calibration information stored in the compass module memory is not within the normal range after a power-up cycle, the compass will display CAL. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 10067 The CT/CMTC/EVIC will enter into the fast-cal mode until calibration is complete. To enter the compass into Manual Calibration mode, perform the following steps: - Drive the vehicle to an area away from any large metal objects or overhead power lines. - Ensure that the proper variance zone is selected. See "Setting Magnetic Zone Variance". - The ignition switch must be in the On position and the CMTC/EVIC display must not be blank. - Press the C/T button to view the Compass/ Temperature display. - Press and hold the RESET button (approximately 10 seconds) until CAL is displayed, then release the button. - Drive slowly, less than 5 MPH (8 KPH) in at least 1 complete 360-degree circle. - CAL will remain illuminated to alert the driver that the compass is in the calibration mode. - After calibration is complete, CAL will turn off. NOTE: For C/T Manual Calibration, perform the same procedure as above, but press and hold the C/T and US/M buttons until CAL is displayed. If the compass appears blank, unable to be calibrated, or the compass displays false indications,the vehicle must be demagnetized. SELF-CHECK DIAGNOSTICS The CT/CMTC/EVIC is capable of performing a diagnostic self check on its internal functions. Diagnostics may be performed using a DRBIII(R) or by using the following procedure: 1. For CMTC/EVIC: With the ignition switch in the OFF position, depress and hold the RESET and the STEP buttons. For CT: With the ignition switch in the OFF position, depress and hold the C/T and the US/M buttons. 2. Turn the ignition switch to the ON position. 3. Continue to hold both buttons until the software versions are displayed, then release the buttons. 4. All of the VFD segments will illuminate for 2-4 seconds. Check for segments that do not illuminate or illuminate all the time. 5. When the self-check is complete the EVIC will display one of the following messages: - PASS SELF TEST - FAILED SELF TEST - NOT RECEIVING J1850 MESSAGE When the self-check is complete the CT/CMTC will display one of the following messages: - PASS - FAIL - BUS 1. To exit the self-check mode: For the CMTC/EVIC: Depress the STEP or RESET button, or cycle the ignition switch and the CMTC/EVIC will return to normal operation. For the C/T: Depress the C/T or US/M button, or cycle the ignition switch and the CT will return to normal operation. If a Communication fault is displayed, refer to the symptom list. If a FAIL or FAILED is displayed, the CT/CMTC/EVIC must be replaced. AMBIENT TEMPERATURE SENSOR The ambient air temperature is monitored by the FCM and displayed by the CT/CMTC/EVIC. The FCM receives a hardwire input from the ambient temperature sensor (ATS). The ATS is a variable resistor that operates on a 5-volt reference signal circuit hardwired from the FCM. The resistance in the ATS changes as the outside temperature rises or falls. The FCM senses the change in reference voltage through the ATS resistor. Based on the resistance of the ATS, the FCM is programmed to correspond to a specific temperature. The FCM stores and filters the ambient temperature data and transmits this data to the CMTC/EVIC via the PCI Bus. The ATS cannot be adjusted or repaired and, if faulty or damaged, it must be replaced. AMBIENT TEMPERATURE SENSOR FAULT CODES The outside temperature function is supported by the ambient temperature sensor (ATS), a signal and ground circuit hardwired to the FCM, and the CMTC/EVIC display. If the ATS sense circuit is shorted to ground, the temp display will be 54° C (130° F) to indicate SHORT circuit condition. If the ATS sense circuit is open, the temp display will be -40° C (-40° F) to indicate an OPEN circuit condition. If there is an OPEN or SHORT circuit condition, it must be repaired before the CMTC/EVIC VFD can be tested. The ATS is supported by the FCM. Ambient Temperature Sensor DTC's will be recorded in the FCM. The ATS can be diagnosed using the following Sensor Test. Test the ATS circuits using the diagnostics in the Body Diagnostic Procedures Manual. If the CMTC/EVIC passes the self-test, and the ATS, the circuits, and PCI bus communications are confirmed to be OK, but the CMTC/EVIC temperature display is inoperative or incorrect, replace the FCM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 10068 AMBIENT TEMPERATURE SENSOR TEST 1. Turn the ignition OFF. 2. Disconnect the ATS harness connector. 3. Measure the resistance of the ATS using the following min/max values: 0° C (32° F) Sensor Resistance = 29.33 - 35.99 Kilohms - 10° C (50° F) Sensor Resistance = 17.99 - 21.81 Kilohms - 20° C (68° F) Sensor Resistance = 11.37 - 13.61 Kilohms - 25° C (77° F) Sensor Resistance = 9.12 - 10.86 Kilohms - 30° C (86° F) Sensor Resistance = 7.37 - 8.75 Kilohms - 40° C (104° F) Sensor Resistance = 4.90 - 5.75 Kilohms The sensor resistance should read between these min/max values. If the resistance values are not OK, replace the Sensor. HOMELINK(R) UNIVERSAL TRANSMITTER If equipped, HomeLink(R) Universal Transmitter is integrated into the overhead console. For added security it will operate home security systems that use coded signals known generically as Rolling Codes. The overhead console display provides visual feedback to the driver, indicating which HomeLink(R) transmitter channel button is being pressed. The HomeLink(R) can learn and store up to three separate transmitter radio frequency codes to operate garage door openers, security gates, and security lighting. The HomeLink(R) buttons are marked with one, two, or three dots. For complete information. TIRE PRESSURE MONITORING SYSTEM (TPMS) If equipped with the Tire Pressure Monitoring System (TPMS), each of the vehicles four wheels will have a valve stem with a pressure sensor and radio transmitter built in. Signals from the tire pressure Sensor/Transmitter are received and interpreted by the Sentry Key Remote Entry Module (SKREEM). Using the DRBIII(R), go to ANTI-THEFT for the SKREEM data. A Sensor/Transmitter in a mounted wheel will broadcast an RF frequency indicating its pressure once per minute when the vehicle is in drive mode. To activate the Sensor/Transmitter operation, the required SKREEM speed is 13 mph (20 km/h). Each Sensor/Transmitters broadcast is uniquely coded so that the SKREEM can monitor the states of each Sensor/Transmitter on the vehicle. The SKREEM TPMS does not use a magnet to relearn, it automatically learns while driving after a SKREEM or a Sensor/Transmitter has been replaced. TRAINING THE SKREEM If a Sensor/Transmitter is replaced, the vehicle has to be parked for at least 15 minutes for the system to be ready to learn the new Sensor/Transmitter ID code. The vehicle then must be driven for a minimum of five minutes with a minimum continuous speed above 13 mph (20 km/h). The system will learn the new Sensor/Transmitter and clear the DTC's automatically. The Sensor/ Transmitters are programmed at the assembly plant in this clockwise orientation: Sensor/Transmitter 1 = Left Front Sensor/Transmitter 2 = Right Front Sensor/Transmitter 3 = Right Rear Sensor/Transmitter 4 = Left Rear NOTE: 1. If one or all Sensor/Transmitters cannot be trained, check for and avoid RF interference. 2. If one Sensor/Transmitter still cannot be trained, replace it and retry. 3. If all Sensor/Transmitters still fail to train, replace the SKREEM. PRESSURE THRESHOLDS The SKREEM will monitor the tire pressure signals from the Sensor/Transmitters and determine if any tire has gone below the low-pressure or above the high-pressure thresholds. Refer to the tables below: Low Tire Pressure Thresholds Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 10069 High Tire Pressure Thresholds *Tolerance ±6.9 kPa (1 PSI) ACTIVE FAULT AND SYSTEM ALERTS An active fault will be triggered when a system failure has been detected. When this occurs, the Instrument Cluster will illuminate the TPMS indicator and the SKREEM will store the fault code. An alert will be triggered when a tire pressure has gone below or above the set threshold pressure. When this occurs, the Instrument Cluster will flash the TPMS indicator. The SKREEM will request a secondary message to be displayed on the EVIC (if equipped). Only when a tire pressure has gone below the set threshold pressure will the SKREEM request the TPMS indicator to flash and display the EVIC message (if equipped). When a high pressure alert occurs, only the EVIC message will be displayed. This action will be displayed as long as the alert condition is active. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Overhead Console > Page 10070 Driver/Vehicle Information Display: Description and Operation Universal Transmitter A Universal Transmitter transceiver is available on some vehicles. The universal transmitter transceiver is integral to the Electronic Vehicle Information Center (EVIC) and the Compass Mini-Trip Computer (CMTC) modules, which are located in the overhead console. The only visible component of the universal transmitter are the three transmitter push buttons centered between the modules push buttons located just rearward of the display screen in the overhead console. The three universal transmitter push buttons are identified with one, two or three light indicators so that they can be easily identified. Each of the three universal transmitter push buttons controls an independent radio transmitter channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 286 to 399 MegaHertz (MHz) frequency range for remote operation. The universal transmitter is capable of operating systems using either rolling code or non-rolling code technology. The electronics module displays messages and a small house-shaped icon with one, two or three dots corresponding to the three transmitter buttons to indicate the status of the universal transmitter. The EVIC messages are: - Cleared Channels - Indicates that all of the transmitter codes stored in the universal transmitter have been successfully cleared. - Training - Indicates that the universal transmitter is in its transmitter learning mode. - Trained - Indicates that the universal transmitter has successfully acquired a new transmitter code. - Transmit - Indicates that a trained universal transmitter button has been depressed and that the universal transmitter is transmitting. The universal transmitter cannot be repaired, and is available for service only as a unit with the EVIC or CMTC modules. If any of these components is faulty or damaged, the complete EVIC or CMTC module must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Component Tests and General Diagnostics Driver/Vehicle Information Display: Component Tests and General Diagnostics Electronic Vehicle Information Center Electronic Vehicle Information Center (EVIC) data is obtained from the Body Control Module (BCM) on the Programmable Communications Interface (PCI) Data Bus circuit. The EVIC will display dashes (- -) for any of the screens it did not receive the bus messages. The label corresponding to the missing information will be lit. If no EVIC data is displayed, check the PCI Data Bus circuit communications and the BCM. If the dimming level is improper check the PCI Data Bus circuit. The use of a DRBIII(R) scan tool and the proper diagnostic procedures information are recommended for further testing of the EVIC module and the PCI data bus circuit. Perform the SELF-DIAGNOSTIC TEST before replacing the EVIC module. Overhead Console Any diagnosis of the overhead console should begin with the use of the DRB III(R) diagnostic tool. For information on the use of the DRB III(R), refer to the appropriate Diagnostic Procedures information. If the problem with the overhead console is an inaccurate or dashed (- -) display, refer to SELF-DIAGNOSTIC TEST. If the problem with the overhead console is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a DRB III(R) scan tool and the proper diagnostic procedures information to test for the correct dimming message inputs being received from the Body Control Module (BCM) or Front Control Module (FCM) over the Programmable Communications Interface (PCI) data bus circuit. If the problem is a no-display condition, use the following procedures. Inspect the related wiring harness connectors for broken, bent, pushed out, or corroded terminals. Refer to the appropriate wiring information. 1. Check the fused B(+) fuse in the integrated power module. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check for battery voltage at the fused B(+) fuse in the integrated power module. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the fused B(+) fuse in the integrated power module as required. 3. Check the fused ignition switch output (run/ start) fuse in the integrated power module. If OK, go to Step 4. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 4. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run/start) fuse in the integrated power module. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run/start) circuit to the ignition switch as required. 5. Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Remove the overhead console. Check for continuity between the ground circuit cavity of the roof wire harness connector for the electronics module and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit as required. 6. Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the roof wire harness connector for the electronics module. If OK, go to Step 7. If not OK, repair the open fused B(+) circuit to the fused B(+) fuse in the integrated power module as required. 7. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run/start) circuit cavity of the roof wire harness connector for the electronics module. If OK, refer to SELF-DIAGNOSTIC TEST. If not OK, repair the open fused ignition switch output (run/start) circuit to the fuse in the integrated power module as required. SELF-DIAGNOSTIC TEST A self-diagnostic test is used to determine that the electronics module is operating properly, and that all the PCI data bus messages are being received for initial operation. Initiate the self-diagnostic test as follows: 1. With the ignition switch in the Off position, on Electronic Vehicle Information Center (EVIC) and Compass Mini-Trip Computer (CMTC) equipped vehicles simultaneously depress and hold the STEP and the RESET buttons. On Compass Temperature Module (CT) equipped vehicles depress the C/T and the US/M push buttons. 2. Turn the ignition switch to the On position. 3. Following completion of these tests, the electronics module will display one of the following messages: a. Pass Self Test (EVIC only), PASS (CT, CMTC) - The electronics module is working properly. b. Failed Self Test (EVIC only), FAIL (CT, CMTC) - The electronics module has an internal failure. The electronics module is faulty and must be replaced. NOTE: - If the compass functions, but accuracy is suspect, it may be necessary to perform a variation adjustment. This procedure allows the compass unit to accommodate variations in the earth's magnetic field strength, based on geographic location. - If the compass reading display is blank and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Universal Transmitter Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 10073 Radio Frequency Detector If both the Universal Transmitter and the Electronic Vehicle Information Center (EVIC) are inoperative. If the Universal Transmitter is inoperative, but the EVIC is operating normally, retrain the Transmitter with a known good transmitter. If the unit is still inoperative, test the universal transmitter with the Radio Frequency Detector special tool as described below: 1. Turn the Radio Frequency (RF) Detector ON. A "chirp" will sound and the green power LED will light. If the green LED does not light, replace the battery. 2. Hold the RF detector within one inch of the TRAINED universal transmitter and press any of the transmitters buttons. 3. The red signal detection LEDs will light and the tool will beep if a radio signal is detected. Repeat this test three times. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 10074 Driver/Vehicle Information Display: Programming and Relearning Programming Transmiter Codes 1. Turn off the engine. 2. Erase the codes by pressing the two outside buttons. Release the buttons when the display confirms the operation (about 20 seconds). 3. Choose one of the three buttons to train. Place the hand-held transmitter within one inch of the universal transmitter and push the buttons on both transmitters. 4. Release both buttons. Your universal transmitter is now "trained". To train the other buttons, repeat Step 3 and Step 4. Be sure to keep your handheld transmitter in case you need to retrain the universal transmitter. Erasing Transmitter Codes To erase the universal transmitter codes, simply hold down the two outside buttons until the display confirms the operation. NOTE: Individual channels cannot be erased. Erasing the transmitter codes will erase ALL programmed codes. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Electronic Vehicle Information Center Programming Driver/Vehicle Information Display: Service and Repair Electronic Vehicle Information Center Programming Some vehicles are equipped with a Electronic Vehicle Information Center (EVIC) equipped overhead console. The Electronic Vehicle Information Center (EVIC) provides the vehicle operator with a user interface, which allows the selection of several optional customer programmable electronic features to suit individual preferences. The EVIC must be placed into its programming mode in order to view or change the programmable features. To enter the EVIC programming mode and to view or change the selected programmable features options, proceed as follows: 1. Turn the ignition switch to the On position. 2. Depress and release the Menu push button. The first item in the programmable features menu list will appear in the EVIC display. 3. Momentarily depress and release the Menu push button to step through the programmable features list. Each programmable feature and its currently selected option will appear on the EVIC display in the sequence shown in the Programmable Features list that follows. 4. Momentarily depress and release the Step push button to step through the available options for the programmable feature being displayed. 5. The option that last appears in the display with a programmable feature before exiting the programming mode, becomes the newly selected programmable feature option. 6. The EVIC exits the programming mode and returns to its normal operating mode when the C/T push button is depressed or when the end of the programmable features menu list is reached, whichever occurs first. PROGRAMMABLE FEATURES NOTE: Tire pressure monitoring (TPM) system information is not covered. Refer to the tires/wheels of this manual for detailed tire pressure monitoring system information. - LANGUAGE? - The options include English, Francaise, Deutsch, Italiana, or Espanol. The default is English. All EVIC display nomenclature, including the trip computer functions, warning messages and the programmable features appear in the selected language. - DISPLAY U.S. OR METRIC? - The options include U.S. and M. The default is U.S. This feature toggles the trip computer temperature, fuel economy and odometer display readings between U.S. and metric units of measure. It also changes the odometer display in the instrument cluster. - SERVICE INTV. = - The options include from 3200 to 12000 kilometers in 800 kilometer increments (2000 to 7500 miles in 500 mile increments). The default is 12000 kilometers (7500 miles). The selected distance becomes the interval at which the Perform Service warning message will be displayed by the EVIC. If a new distance is selected, a second programmable feature appears, RESET SERVICE DISTANCE? - The options include No and Yes. The default is Yes. When Yes is selected, the accumulated distance since the last previous Perform Service warning message will be reset to zero because the service interval has been changed. When No is selected, the distance until the next Perform Service warning message is reduced by the accumulated distance since the last previous message. - USE FACTORY SETTINGS? - The options include Yes and No. The default is Yes. When yes is selected all the programmable features will return to there defaults and the rest of the programmable features will not be displayed. If No is selected the rest of the programmable features will be displayed at there current chosen values. This feature will automatically return to the Yes default under two conditions. First, if no programmable features are changed from there defaults. Second, if all the programmable features equal there defaults. - AUTO DOOR LOCKS? - The options include Yes and No. The default is Yes. When Yes is selected, all doors and the liftgate lock automatically when vehicle speed reaches 25 kilometers-per-hour (15 miles-per-hour). If YES is selected, a second programmable feature appears, AUTO UNLOCK ON EXIT? - The options again include Yes and No. The default is No. When Yes is selected, following each Auto Door Lock event all doors and the liftgate will automatically unlock when the driver door is opened, if the vehicle is stopped and the transmission gear selector is in Park or Neutral. The Auto Door Unlock event will only occur once following each Auto Door Lock event. - REMOTE UNLOCK - The options include Driver Door 1st and All Doors. The default is Driver Door 1st. When Diver Door 1st is selected, only the driver door unlocks when the Unlock button of the Remote Keyless Entry (RKE) transmitter is depressed once. The Unlock button of the RKE transmitter must be depressed twice to unlock all doors. When All Doors is selected, all doors unlock when the Unlock button of the RKE transmitter is depressed once. - REMOTE LINKED TO MEMORY? - This programmable feature only applies to vehicles equipped with the optional memory / heated system. The options include Yes and No. The default is No. When Yes is selected, the memory system will recall the Driver 1 or Driver 2 memory settings assigned to the RKE transmitter being used to unlock the vehicle. When No is selected, the memory system will only recall memory settings when the Driver 1 or Driver 2 push buttons of the memory switch on the driver side front door trim panel are depressed. - SOUND HORN ON LOCK? - The options include Yes and No. The default is No. When Yes is selected, a short horn chirp will provide an audible confirmation when the RKE receiver recognizes a valid Lock signal from an RKE transmitter. When No is selected, no horn chirp will occur with the RKE Lock event. This feature may be selected independent of the FLASH LIGHTS WITH LOCKS? programmable feature. - FLASH LIGHTS WITH LOCKS? - The options include Yes and No. The default is Yes. When Yes is selected, a single flash of the hazard warning lamps will provide an optical confirmation when the RKE receiver recognizes a valid Lock signal from an RKE transmitter, and two flashes of the same lamps will occur when the RKE receiver recognizes a valid Unlock signal from an RKE transmitter. When No is selected, no lamp flash will occur with the RKE Lock or Unlock event. This feature may be selected independent of the SOUND HORN ON LOCK? programmable feature. - HEADLAMP DELAY = - The options include Off, 30 Sec, 60 Sec, and 90 Sec. The default is 90 Sec. When a time interval is selected, the headlamps will remain on for that length of time when the headlamps are turned off after the ignition is turned off, or if the Auto mode is selected on vehicles with the Auto Headlamps option. When Off is selected, the headlamp delay feature is disabled. - HEADLAMPS ON WITH WIPERS? - This programmable feature only applies to vehicles equipped with the optional Auto Headlamps. The options include Yes and No. The default is No. When Yes is selected, the headlamps will turn on automatically when the windshield wipers are turned on. The headlamps will turn off when the wipers are turned off, as long as the headlamp switch is in the Auto or Off positions. When No is selected, the headlamps will only turn on if manually selected or if the Auto mode is selected and the outside ambient light levels dictate that they should be on. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Electronic Vehicle Information Center Programming > Page 10077 - POWER ACCESSORY DELAY? - The options include Yes and No. The default is Yes. When No is selected, the accessory powered components will turn off automatically when the ignition key is turned off. When Yes is selected, the accessory powered components will remain on for 45 seconds when the ignition key is turned off. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Electronic Vehicle Information Center Programming > Page 10078 Driver/Vehicle Information Display: Service and Repair Electronic Vehicle Info Center REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove overhead console. 3. Remove the ten screws holding the Electronic Vehicle Information Center (EVIC) module in the overhead console. 4. Remove EVIC module from console assembly. NOTE: If the EVIC module is being replaced, the tire pressure monitoring system (if equipped) must be retrained. INSTALLATION 1. Position the Electronic Vehicle Information Center (EVIC) module in the overhead console. 2. Install the ten screws holding the EVIC module in the overhead console. 3. Install the overhead console. 4. Connect the battery negative cable. NOTE: If the EVIC module is being replaced, the tire pressure monitoring system (if equipped) must be retrained. - If a new EVIC module has been installed, the compass will have to be calibrated and the variance set. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation Air Bag(s) Arming and Disarming: Technical Service Bulletins Air Bag System - Passenger Air Bag Deactivation NUMBER: 08-001-07 REV. B GROUP: Electrical DATE: May 16, 2007 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-001-07 REV. A, DATED FEBRUARY 7, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN INCLUDED. THIS INFORMATION IS PROVIDED FOR COUNTRIES OUTSIDE OF THE UNITED STATES, PLEASE FOLLOW LOCAL LAWS GOVERNING AIRBAG DEACTIVATION. DUE TO U.S. FEDERAL LAW, IT IS ILLEGAL FOR A U.S. DEALER TO INSTALL THESE PARTS ON U.S. VEHICLES. FOR VEHICLES WITHIN THE UNITED STATES, CONTACT NHTSA'S AUTO SAFETY HOTLINE AT 1-800-424-9393 FOR GUIDELINES REGARDING AIRBAG DEACTIVATION. SUBJECT: Passenger Air Bag Deactivation MODELS: 2007 - 2008 (JK) Wrangler/Wrangler Unlimited 2007 - 2008 (KA) Nitro 2002 - 2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2006 - 2007 (LE) 0300/Touring (International Markets) 2005 - 2007 (LX) 300/Magnum/Charger 2001 - 2008 (PT/PG) Chrysler PT Cruiser/Chrysler PT Cruiser (International Markets) 2004 - 2007 (RG) Chrysler Voyager (International Markets) 2004 - 2007 (RS) Town & Country/Caravan/Voyager 2005 - 2007 (WH) Grand Cherokee (International Markets) 2005 - 2007 (WK) Grand Cherokee 2006 - 2007 (XH) Commander (International Markets) 2006 - 2007 (XK) Commander 2006 - 2007 (HB/HG) Durango/Aspen 2006 - 2007 (ND) Dakoka 2006 - 2007 (DR) Ram Truck 2005 - 2007 (CS) Pacifica 2007 (PM) Caliber 2007 (MK49) Compass 2007 (MK74) Patriot 2007 (JS) Sebring Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 10084 2007 - 2008 (JS) Avenger 2008 (JS27) Sebring Convertible NOTE: THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY TO DEACTIVATE PASSENGER AIRBAGS IN COUNTRIES OUTSIDE OF THE UNITED STATES. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR PART WARRANTY. DISCUSSION: DaimlerChrysler Corporation is now offering a passenger airbag deactivation wiring package for the selected vehicles listed above operating outside of the United States. The wiring package is a kit containing all necessary parts and a detailed instruction sheet. NOTE: Due to U.S. law and the inability for U.S. dealers to legally install these parts on U.S. vehicles, orders for the following parts will only be accepted from dealers outside of the United States. PARTS REQUIRED: POLICY: Information Only Disclaimer: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Air Bag System - Passenger Air Bag Deactivation > Page 10085 This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Technical Service Bulletins > Page 10086 Air Bag(s) Arming and Disarming: Service and Repair AIRBAG ARMING AND DISARMING WARNING: The airbag control module contains the impact sensor, which enables the system to deploy the airbag. Before attempting to diagnose or service any airbag system or related steering wheel, steering column, or instrument panel components, you must disable the airbag system. PROCEDURE 1. Disconnect and isolate the battery negative (ground) cable. 2. Wait at least two minutes for the capacitor to discharge. WARNING: This is the only sure way to disable the airbag system. Failure to do this could result in accidental airbag deployment and possible personal injury. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Beam Indicator > Component Information > Diagrams Low Beam Indicator: Diagrams Left Low Beam Lamp (Export) Right Low Beam Lamp (Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Service and Repair Low Tire Pressure Indicator: Service and Repair Inspect all tire for proper inflation pressure, once proper tire pressure has been set the TPM system warning will reset automatically once the ignition switch has been turned ON. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Service and Repair Maintenance Required Lamp/Indicator: Service and Repair Service Interval When this feature is selected, a service interval between 2,000 (3,200 km) and 6,000 miles (9,600 km) in 500 mile (800 km) increments may be selected. Pressing the STEP button when in this display will select distances between 2,000 (3,200 km) and 6,000 miles (9,600 km) in 500 mile (800 km) increments. Reset Service Distance (Displays Only if Service Interval was Changed) When this feature is selected the current accumulated service distance can be reset to the newly selected service interval. Pressing the STEP button when in this display will select "Yes" or "No." Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications Oil Pressure Sender: Specifications Oil Pressure Switch ............................................................................................................................. .................................................. 23 Nm (200 in. lbs.) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 10099 Oil Pressure Sender: Description and Operation DESCRIPTION The engine oil pressure switch is located on the lower left front side of the engine. It screws into the oil filter adapter. The normally closed switch provides an input through a single wire to the low pressure indicator light on the instrument cluster. OPERATION The oil pressure switch provides a ground for the instrument cluster low oil pressure indicator light. The switch receives oil pressure input from the engine main oil gallery. When engine oil pressure is greater than 27.5 Kpa (4 psi), the switch contacts open, providing a open circuit to the low pressure indicator light. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Specifications > Page 10100 Oil Pressure Sender: Service and Repair REMOVAL 1. Raise vehicle on hoist. 2. Disconnect electrical connector from switch. 3. Remove oil pressure switch (Fig. 110). INSTALLATION 1. Install oil pressure switch. Torque oil pressure switch to 23 Nm (200 in. lbs.) (Fig. 110). 2. Connect electrical connector to switch. 3. Lower the vehicle. 4. Start engine and check for leaks. 5. Check engine oil level. Adjust as necessary. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Application and ID Oil Pressure Warning Lamp/Indicator: Application and ID BULB APPLICATION Oil Indicator (Base Cluster ................................................................................................................... ....................................................................... LED Oil Indicator ......................................................... ...................................................................................................................................................... PC74 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Locations Parking Brake Warning Lamp: Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Locations > Page 10111 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations Right B Pillar Left B Pillar Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 10116 Driver Door Passenger Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 10117 Right Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 10118 Liftgate Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 10119 Door Switch: Diagrams Hood Ajar Switch (Export) Left Front Ajar Switch (Base) Left Front Door Lock Motor/Ajar Switch (Except Base) Right Front Door Switch Ajar Switch (Base) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 10120 Right Front Door Lock Motor/Ajar Switch (Except Base) Right Sliding Door Lock Motor/Ajar Switch (Manual Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH Technical Service Bulletin # 21-022-05 Date: 051104 Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH NUMBER: 21-022-05 GROUP: Transmission DATE: November 4,2005 SUBJECT: Inaccurate Speedometer OVERVIEW: This bulletin may involve replacing the transfer gear set, erase any Diagnostic Trouble Codes (DTC) and resetting the pinion factor. MODELS: 2005 (RS) Town & Country/Caravan/Voyager NOTE: This bulletin applies to RS vehicles equipped with a 3.3L engine (sales code EGA or EGM) and an automatic transmission (sales code DGL). NOTE: This bulletin only applies to vehicles that have had previous transmission repair work involving the transfer gear set or differential assembly gear set. SYMPTOM/CONDITION: The vehicles speedometer may be inaccurate by as much as 6 m.p.h. at a vehicle speed of 50 m.p.h. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all transmission systems are functioning as designed. If any speed sensor related DTC is present record them on the repair order and repair as necessary before proceeding further with this service bulletin. If the vehicle operator describes or experiences the Symptom/Condition check the repair history. If the vehicle has been serviced for a transfer gear set or differential assembly gear set then it will be necessary to perform the Repair Procedure. NOTE: Ask the customer if they have had any transmission service performed by a non-Chrysler, Dodge or Jeep dealer, to determine if the transfer gear set or the differential gear set has been serviced. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10132 SPECIAL TOOLS/EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure NOTE: Be sure there are no speed sensor(s) related DTCs present before proceeding further with this service bulletin. 1. Raise the vehicle on a suitable hoist. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10133 2. Remove transfer gear cover-to-case bolts and catch any transmission fluid which may drain in a suitable container (Fig. 1). 3. Remove transfer gear cover (Fig. 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10134 4. Remove the differential cover and bolts (Fig. 3) and (Fig. 4). 5. Count the number of teeth on both the ring gear and the transfer gear. 6. Does the ring gear have 63 teeth and the transfer gear have 46 teeth? a. Yes >> further diagnosis is required. This service bulletin does not apply b. No >> go to Step # 7. 7. Does the ring gear have 59 teeth and the transfer gear have 49 teeth? a. Yes >> further diagnosis is required. This service bulletin does not apply b. No >> go to Step # 8. NOTE: If the ring gear has 63 teeth and the transfer gear has 49 teeth then you must replace the transfer gear set with part 04713443AC. NOTE: If the ring gear has 59 teeth and the transfer gear has 46 teeth then you must replace the transfer gear set with part 04713444AD. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10135 8. Using Tool 6259, remove transfer shaft gear-to-shaft nut and coned washer (Fig. 5) and (Fig. 6). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10136 9. Using tool L-4407A, remove transfer shaft gear (Fig. 7). 10. Remove transfer gear and shim (select) (Fig. 8). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10137 11. Draw or scribe a line from the indexing slot on the bearing cup retainer to the transfer cover bolt flange. (THIS WILL ALLOW THE BEARING RETAINER TO BE INSTALLED IN THE ORIGINAL POSITION SHOULD IT COME OUT.(Fig. 9). 12. Remove stirrup and strap and bolts. 13. Using tools L-4407 and 6259 remove the output gear bolt, washer and shim. 14. Install gauging shim .177" (4.50 mm), PN 4412832, and new output gear (lubricate bearing with ATF+4 before installing on output shaft) using old bolt & washer. Torque to 200 ft.lbs. (271 N-m). NOTE: Shim thickness should be verified with a micrometer. 15. Attach tool L-4432 to the output gear, push and pull on the gear while turning it back and forth to assure the bearing rollers are seated. 16. Measure the end play of the output gear bearing using a dial indicator attached to the transaxle case and record end play. 17. Using an inch-pound torque wrench, check and record the output gear turning torque. 18. With output bearing turning torque determined, refer to the Output Gear Bearing Shim Chart Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10138 OUTPUT GEAR BEARING SHIM CHART 19. Using tools L4407 & 6259, remove output gear, bolt and washer. 20. Remove gauging shim and install the proper shim selected in Step # 18. Verify the shim thickness with a micrometer before installing. Using the old retaining bolt and washer, torque to 200 ft.lbs. (271 N-m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10139 21. Using a dial indicator measure output gear end play. If end play is zero, go to Step # 22. If end play exists, repeat Step # 13 to Step # 21. 22. Using an inch-pound torque wrench, check and record the output gear turning torque. 23. Subtract the torque value recorded in Step # 17 from the torque value recorded in Step # 22. The difference must be 3 to 8 inch pounds. NOTE: This is the output bearing turning torque. 24. If the turning torque is too high, install a 0.04 mm (.0016 in.) thicker shim. If the turning torques is too low, install a 0.04 mm (.0016 in.) thinner shim. Repeat until the difference Step # 23 is 3-8 inch pounds. 25. Remove the old retaining bolt & washer and discard. Install the new retaining bolt & washer and tighten to 271 N.m (200 ft. lbs.). 26. Install stirrup and strap and bolts. 27. Install a 4.66 mm (0.183 in.) gauging shim, p/n 4505588, onto the transfer shaft. NOTE: Before install the gear make sure the bearing cup retainer index slot lines up with the mark made in Step # 11. 28. Lubricate the bearing on the new transfer gear with ATF, and install the gear using the old retainer nut and washer. Tighten the retaining nut to 271 N.m (200 ft.lbs.). 29. Measure the transfer shaft end play as follows: a. Install Miller special tool L-4432 to the transfer gear. b. Install a greased steel ball in the end of the transfer shaft. (To aid in measuring transfer shaft end play). c. Push and pull the gear while rotating back and forth to insure the bearing rollers are seated. d. Using a dial indicator, measure the transfer shaft end play. 30. Refer to the Transfer Shaft Bearing Shim Chart for the required shim combination to obtain the proper bearing setting. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10140 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10141 TRANSFER SHAFT BEARING SHIM CHART 31. Remove the transfer gear using Miller Special Tools L-4407 & 6259. 32. Remove the gauging shim and install the selected shim combination from Step # 30. 33. Install the transfer gear making sure the bearing cup retainer is properly indexed, torque the retainer bolt to 271 N-m (200 ft.lbs.). NOTE: The retainer index tab can be viewed through the large hole in the gear. 34. Measure the transfer shaft end play as follows: a. Install Miller special tool L-4432 to the transfer gear. b. Install a greased steel ball in the end of the transfer shaft. (To aid in measuring transfer shaft end play). c. Push and pull the gear while rotating back and forth to insure the bearing rollers are seated. d. Using a dial indicator, measure the transfer shaft end play. 35. End play should be 0.05 to 0.10 mm (0.002 to 0.004 in.). Is the end play too high? a. Yes >> install a 0.04 mm (0.0016 in) thinner shim. Repeat until 0.05 to 0.10 mm (0.002 to 0.004 in.) is obtained. b. No >> go to Step # 36. 36. Is the end play too low? a. Yes» install a 0.04 mm (0.0016 in) thicker shim. Repeat until 0.05 to 0.10 mm (0.002 to 0.004 in.) is obtained. b. No >> go to Step # 37. 37. Remove the steel ball installed in Step # 34b. 38. Remove the old retaining nut & washer and discard. Install the new retaining nut & washer supplied and tighten to 271 N-m (200 ft.lbs.). 39. Install a bead of Mopar(R) ATF RTV (MS-GF41) to transfer gear cover and install the cover (Fig. 2). 40. Install transfer gear cover-to-case bolts and torque to 20 N-m (175 in. lbs.) torque (Fig. 1). 41. Lower the vehicle. 42. Fill transaxle with suitable amount of ATF+4 (Automatic Transmission Fluid - Type 9602). Refer to the detailed service information available in Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10142 TechCONNECT, under: Service Info, 21 - Transmission/Transaxle/Automatic - 41 TE/Fluid Standard Procedure 43. Using the DRBIII(R) erase any diagnostic trouble codes (DTC) and reset the pinion factor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH Technical Service Bulletin # 21-022-05 Date: 051104 Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH NUMBER: 21-022-05 GROUP: Transmission DATE: November 4,2005 SUBJECT: Inaccurate Speedometer OVERVIEW: This bulletin may involve replacing the transfer gear set, erase any Diagnostic Trouble Codes (DTC) and resetting the pinion factor. MODELS: 2005 (RS) Town & Country/Caravan/Voyager NOTE: This bulletin applies to RS vehicles equipped with a 3.3L engine (sales code EGA or EGM) and an automatic transmission (sales code DGL). NOTE: This bulletin only applies to vehicles that have had previous transmission repair work involving the transfer gear set or differential assembly gear set. SYMPTOM/CONDITION: The vehicles speedometer may be inaccurate by as much as 6 m.p.h. at a vehicle speed of 50 m.p.h. DIAGNOSIS: Using a Scan Tool (DRBIII(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all transmission systems are functioning as designed. If any speed sensor related DTC is present record them on the repair order and repair as necessary before proceeding further with this service bulletin. If the vehicle operator describes or experiences the Symptom/Condition check the repair history. If the vehicle has been serviced for a transfer gear set or differential assembly gear set then it will be necessary to perform the Repair Procedure. NOTE: Ask the customer if they have had any transmission service performed by a non-Chrysler, Dodge or Jeep dealer, to determine if the transfer gear set or the differential gear set has been serviced. PARTS REQUIRED: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10148 SPECIAL TOOLS/EQUIPMENT REQUIRED: POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Repair Procedure NOTE: Be sure there are no speed sensor(s) related DTCs present before proceeding further with this service bulletin. 1. Raise the vehicle on a suitable hoist. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10149 2. Remove transfer gear cover-to-case bolts and catch any transmission fluid which may drain in a suitable container (Fig. 1). 3. Remove transfer gear cover (Fig. 2). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10150 4. Remove the differential cover and bolts (Fig. 3) and (Fig. 4). 5. Count the number of teeth on both the ring gear and the transfer gear. 6. Does the ring gear have 63 teeth and the transfer gear have 46 teeth? a. Yes >> further diagnosis is required. This service bulletin does not apply b. No >> go to Step # 7. 7. Does the ring gear have 59 teeth and the transfer gear have 49 teeth? a. Yes >> further diagnosis is required. This service bulletin does not apply b. No >> go to Step # 8. NOTE: If the ring gear has 63 teeth and the transfer gear has 49 teeth then you must replace the transfer gear set with part 04713443AC. NOTE: If the ring gear has 59 teeth and the transfer gear has 46 teeth then you must replace the transfer gear set with part 04713444AD. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10151 8. Using Tool 6259, remove transfer shaft gear-to-shaft nut and coned washer (Fig. 5) and (Fig. 6). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10152 9. Using tool L-4407A, remove transfer shaft gear (Fig. 7). 10. Remove transfer gear and shim (select) (Fig. 8). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10153 11. Draw or scribe a line from the indexing slot on the bearing cup retainer to the transfer cover bolt flange. (THIS WILL ALLOW THE BEARING RETAINER TO BE INSTALLED IN THE ORIGINAL POSITION SHOULD IT COME OUT.(Fig. 9). 12. Remove stirrup and strap and bolts. 13. Using tools L-4407 and 6259 remove the output gear bolt, washer and shim. 14. Install gauging shim .177" (4.50 mm), PN 4412832, and new output gear (lubricate bearing with ATF+4 before installing on output shaft) using old bolt & washer. Torque to 200 ft.lbs. (271 N-m). NOTE: Shim thickness should be verified with a micrometer. 15. Attach tool L-4432 to the output gear, push and pull on the gear while turning it back and forth to assure the bearing rollers are seated. 16. Measure the end play of the output gear bearing using a dial indicator attached to the transaxle case and record end play. 17. Using an inch-pound torque wrench, check and record the output gear turning torque. 18. With output bearing turning torque determined, refer to the Output Gear Bearing Shim Chart Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10154 OUTPUT GEAR BEARING SHIM CHART 19. Using tools L4407 & 6259, remove output gear, bolt and washer. 20. Remove gauging shim and install the proper shim selected in Step # 18. Verify the shim thickness with a micrometer before installing. Using the old retaining bolt and washer, torque to 200 ft.lbs. (271 N-m). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10155 21. Using a dial indicator measure output gear end play. If end play is zero, go to Step # 22. If end play exists, repeat Step # 13 to Step # 21. 22. Using an inch-pound torque wrench, check and record the output gear turning torque. 23. Subtract the torque value recorded in Step # 17 from the torque value recorded in Step # 22. The difference must be 3 to 8 inch pounds. NOTE: This is the output bearing turning torque. 24. If the turning torque is too high, install a 0.04 mm (.0016 in.) thicker shim. If the turning torques is too low, install a 0.04 mm (.0016 in.) thinner shim. Repeat until the difference Step # 23 is 3-8 inch pounds. 25. Remove the old retaining bolt & washer and discard. Install the new retaining bolt & washer and tighten to 271 N.m (200 ft. lbs.). 26. Install stirrup and strap and bolts. 27. Install a 4.66 mm (0.183 in.) gauging shim, p/n 4505588, onto the transfer shaft. NOTE: Before install the gear make sure the bearing cup retainer index slot lines up with the mark made in Step # 11. 28. Lubricate the bearing on the new transfer gear with ATF, and install the gear using the old retainer nut and washer. Tighten the retaining nut to 271 N.m (200 ft.lbs.). 29. Measure the transfer shaft end play as follows: a. Install Miller special tool L-4432 to the transfer gear. b. Install a greased steel ball in the end of the transfer shaft. (To aid in measuring transfer shaft end play). c. Push and pull the gear while rotating back and forth to insure the bearing rollers are seated. d. Using a dial indicator, measure the transfer shaft end play. 30. Refer to the Transfer Shaft Bearing Shim Chart for the required shim combination to obtain the proper bearing setting. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10156 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10157 TRANSFER SHAFT BEARING SHIM CHART 31. Remove the transfer gear using Miller Special Tools L-4407 & 6259. 32. Remove the gauging shim and install the selected shim combination from Step # 30. 33. Install the transfer gear making sure the bearing cup retainer is properly indexed, torque the retainer bolt to 271 N-m (200 ft.lbs.). NOTE: The retainer index tab can be viewed through the large hole in the gear. 34. Measure the transfer shaft end play as follows: a. Install Miller special tool L-4432 to the transfer gear. b. Install a greased steel ball in the end of the transfer shaft. (To aid in measuring transfer shaft end play). c. Push and pull the gear while rotating back and forth to insure the bearing rollers are seated. d. Using a dial indicator, measure the transfer shaft end play. 35. End play should be 0.05 to 0.10 mm (0.002 to 0.004 in.). Is the end play too high? a. Yes >> install a 0.04 mm (0.0016 in) thinner shim. Repeat until 0.05 to 0.10 mm (0.002 to 0.004 in.) is obtained. b. No >> go to Step # 36. 36. Is the end play too low? a. Yes» install a 0.04 mm (0.0016 in) thicker shim. Repeat until 0.05 to 0.10 mm (0.002 to 0.004 in.) is obtained. b. No >> go to Step # 37. 37. Remove the steel ball installed in Step # 34b. 38. Remove the old retaining nut & washer and discard. Install the new retaining nut & washer supplied and tighten to 271 N-m (200 ft.lbs.). 39. Install a bead of Mopar(R) ATF RTV (MS-GF41) to transfer gear cover and install the cover (Fig. 2). 40. Install transfer gear cover-to-case bolts and torque to 20 N-m (175 in. lbs.) torque (Fig. 1). 41. Lower the vehicle. 42. Fill transaxle with suitable amount of ATF+4 (Automatic Transmission Fluid - Type 9602). Refer to the detailed service information available in Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 21-022-05 > Nov > 05 > Instruments - Speedometer Inaccurate by 6MPH Over 50 MPH > Page 10158 TechCONNECT, under: Service Info, 21 - Transmission/Transaxle/Automatic - 41 TE/Fluid Standard Procedure 43. Using the DRBIII(R) erase any diagnostic trouble codes (DTC) and reset the pinion factor. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection Temperature Gauge Diagnosis Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Service and Repair Low Tire Pressure Indicator: Service and Repair Inspect all tire for proper inflation pressure, once proper tire pressure has been set the TPM system warning will reset automatically once the ignition switch has been turned ON. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The use of tire sealants is strictly prohibited for vehicles equipped with the Tire Pressure Monitoring system. Tire sealants can clog tire pressure sensors. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: Do not attempt to install a tire pressure sensor in an aftermarket wheel. Use tire pressure sensors in original style factory wheels only. CAUTION: Any time a sensor is to be installed in a wheel, a new seal and washer must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 10169 Tire Pressure Sensor: Description and Operation SENSOR - TPM DESCRIPTION On vehicles equipped with Tire Pressure Monitoring (TPM), one tire pressure sensor is mounted to each wheel in place of the traditional tire valve stem (Fig. 18). Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency (Fig. 18). The TPM sensors are designed for original style factory wheels. Do not attempt to install a tire pressure sensor in an aftermarket wheel. The serviceable components of the tire pressure sensor are (Fig. 19): Sensor-To-Wheel Seal and Metal Washer - Valve Stem Cap - Valve Stem Core - Valve Stem Nut Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 10170 The valve stem caps and cores used are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. OPERATION The battery operated tire pressure sensors lay dormant (Park Mode), then wake and start transmitting (Drive Mode) when the vehicle first reaches speeds over 15 mph (24 km/h). Once the wheels stop rotating for a period of approximately 20 minutes, the sensors shut down until again awaken. Although not transmitting as when in Drive Mode, while in Park Mode, the sensors still transmit approximately once every 13 hours to let the receiver know air pressure status at that time. Using an RF signal, each sensor transmits tire pressure data approximately once every minute. Each sensor's (transmitter) broadcast is uniquely coded so that the Sentry Key Remote Entry Module (SKREEM) can monitor the state of each of the sensors on the four rotating road wheels. The SKREEM automatically learns and stores the sensor's ID while driving after a sensor has been replaced. There is no formal retraining procedure necessary. For additional information, refer to appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 10171 Tire Pressure Sensor: Testing and Inspection DIAGNOSIS AND TESTING - TIRE PRESSURE SENSOR NOTE: Tire pressure may increase from 2 to 6 psi (14 to 41 kPa) during normal driving conditions. Do NOT reduce this normal pressure build up. When diagnosing a tire pressure issue, always check air pressure in the tires first with a known accurate air gauge. Adjust air pressure as necessary to that listed on the Tire Inflation Pressure Label (Placard) provided with the vehicle (usually applied to the driver's side B-pillar). After adjusting air pressure in a tire, allow approximately two minutes for the message or indicator lamp to go out. Check the tire pressure indicator lamp in the instrument cluster. If the lamp is illuminating continuously, proceed as listed. If the indicator lamp is flashing on/off three times, once every ten minutes, there is a system fault detected. Refer to the appropriate diagnostic information. If air pressure in any tire is low, inspect all the tires for leaks. A water "dunk tank" or other water test may be used to check for a leak around the sensor as long as any water at the valve core is removed once the procedure is completed. The water can be easily expelled from the core area by pushing in on the core for several seconds, allowing escaping air to drive out any moisture. Reinflate the tire as necessary. Always make sure the original valve stem cap is securely installed to keep moisture out of the sensor. If the gauge-read pressure in the tires does not indicate a tire pressure issue, refer to the appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 10172 Tire Pressure Sensor: Service and Repair TIRE PRESSURE SENSOR REMOVAL 1. Remove tire and wheel assembly from vehicle. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Retain this valve stem cap for reuse. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 2. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor. That includes both front and rear beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool at the valve stem ± 10° (Fig. 20), then proceed to dismount the tire from the wheel. Use this process on both the upper and lower tire beads. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 10173 3. Remove sensor nut retaining sensor to wheel (Fig. 21). While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 4. Remove sensor from wheel (Fig. 21). INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal and metal washer at base of valve stem to ensure proper sealing (Fig. 22). 1. Wipe area clean around sensor/valve stem mounting hole in wheel. Make sure surface of wheel is not damaged. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 10174 CAUTION: To avoid damaging sensor antenna strap (Fig. 23), hold pressure against rear of metal valve stem (Fig. 24) while sensor is inserted through wheel mounting hole and nut is installed. 2. Insert sensor through wheel as shown keeping pressure against rear of metal valve stem. (Fig. 24). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) by hand (Fig. 24). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 10175 NOTE: Before tightening sensor nut, push downward on sensor housing in an attempt to make it flush with interior contour of wheel (Fig. 25). 4. While holding sensor in position, tighten sensor nut to 6.5 Nm (58 inch lbs.) torque. CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 inch lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function, however, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem approximately 210° from the head of the changer in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire (Fig. 26). Use this procedure on both the upper and lower tire beads. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions > Page 10176 b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem is approximately 210° from the head of the changer in a clockwise direction from the mounting end of the tool (Fig. 27) Make sure the sensor is clear of the lower bead breaker area to avoid damaging the sensor when the breaker rises (Fig. 27). Rotate the tool in a counterclockwise direction to mount the tire. Use this procedure on both the upper and lower tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install wheel and tire assembly on vehicle. 8. Drive vehicle for a minimum of five minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time the system will learn the new sensor ID code and will clear any DTCs automatically. NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams Back-Up Lamp Switch (MTX) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Connector Views Brake Lamp: Connector Views Left Rear Lamp Assembly Right Rear Lamp Assembly Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 10193 Brake Light Switch: Connector Locations Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 10194 Right Side Kick Panel RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10195 Brake Lamp Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10196 Brake Light Switch: Description and Operation ABS AND BRAKE WARNING INDICATORS The amber ABS warning indicator is located in the instrument cluster. It is used to inform the driver that the antilock function has been turned off. The ABS warning indicator is controlled by the CAB/ABM. The CAB/ABM controls the lamp with a command over the PCI bus. The ABS Warning Indicator will remain lit during every key cycle until a circuit or component fault is repaired and the CAB/ABM no longer detects the fault. After repair of a sensor signal fault or a pump motor fault, the CAB/ABM must sense all four wheels at 25 km/h (15 mph) before it will extinguish the ABS and TCS Indicator. The Instrument Cluster will illuminate the ABS Warning Indicator if it loses communication with the CAB/ABM. The red BRAKE warning indicator is also located in the instrument cluster. It can be activated in several ways. Application of the parking brake or a low fluid signal from the fluid level switch located in the master cylinder reservoir will cause the indicator to come on. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams Center High Mounted Stop Lamp Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Console Lamp > Component Information > Diagrams Floor Console Lamp Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Description and Operation Daytime Running Lamp: Description and Operation DAYTIME RUNNING LAMPS Operating the high-beam headlamps at reduced power provides daytime running lamps, which are required on all new Canadian vehicles. Daytime running lamps are functional when 450 rpm's are reached. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams Rear Dome Lamp (Except Luxury) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Right B Pillar Left B Pillar Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 10213 Driver Door Passenger Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 10214 Right Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 10215 Liftgate Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 10216 Door Switch: Diagrams Hood Ajar Switch (Export) Left Front Ajar Switch (Base) Left Front Door Lock Motor/Ajar Switch (Except Base) Right Front Door Switch Ajar Switch (Base) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 10217 Right Front Door Lock Motor/Ajar Switch (Except Base) Right Sliding Door Lock Motor/Ajar Switch (Manual Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Motor > Component Information > Diagrams Headlamp Motor: Diagrams Left Headlamp Leveling Motor (Export) Right Headlamp Leveling Motor (Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 10232 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 10233 Right Side Instrument Panel Lower RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 10234 Headlamp Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Diagrams Left High Beam Lamp (Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Connector Views License Plate Lamp: Connector Views License Lamp (Manual Release) License Lamp (Power Liftgate) License Lamp (Power Release) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Map Light > Component Information > Diagrams Map Light: Diagrams Front Reading Lamps/Switch Left MID Reading Lamp (premium/Luxury) Left Rear Reading Lamp (Luxury) Right MID Reading Lamp (Premium/Luxyry) Right Rear Reading Lamp (Luxury) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay > Component Information > Description and Operation Turn Signal Relay: Description and Operation The turn signal flasher function is incorperated into the Body Control Module (BCM), for further information, refer to Body Control Module for wiring diagrams and Powertrain Management/ Computers and Control Systems/ System Diagnosis/ Diagnostic Trouble Code Tests and Associated Procedures/ Manufacturer Code Charts/ Exterior Lighting. See: Body and Frame/Body Control Systems/Body Control Module See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Exterior Lighting Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams Back-Up Lamp Switch (MTX) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 10277 Brake Light Switch: Connector Locations Left Side Kick Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Component Locations > Page 10278 Right Side Kick Panel RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10279 Brake Lamp Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10280 Brake Light Switch: Description and Operation ABS AND BRAKE WARNING INDICATORS The amber ABS warning indicator is located in the instrument cluster. It is used to inform the driver that the antilock function has been turned off. The ABS warning indicator is controlled by the CAB/ABM. The CAB/ABM controls the lamp with a command over the PCI bus. The ABS Warning Indicator will remain lit during every key cycle until a circuit or component fault is repaired and the CAB/ABM no longer detects the fault. After repair of a sensor signal fault or a pump motor fault, the CAB/ABM must sense all four wheels at 25 km/h (15 mph) before it will extinguish the ABS and TCS Indicator. The Instrument Cluster will illuminate the ABS Warning Indicator if it loses communication with the CAB/ABM. The red BRAKE warning indicator is also located in the instrument cluster. It can be activated in several ways. Application of the parking brake or a low fluid signal from the fluid level switch located in the master cylinder reservoir will cause the indicator to come on. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 10284 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 10285 Steering Column Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 10286 Center Instrument Panel Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 10287 Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 10288 Multi-Function Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description - Turn Signal System Combination Switch: Description and Operation Description - Turn Signal System DESCRIPTION - TURN SIGNAL SYSTEM The turn signals are actuated with a lever on Multi-Function Switch, located on the left side of the steering wheel. The signals are automatically turned off by a canceling cam (two lobes molded to the clock spring mechanism). The cam comes in contact with the cancel actuator on the turn signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. The multi-function switch is a resistive MUX switch that feeds inputs to the BCM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Description - Turn Signal System > Page 10291 Combination Switch: Description and Operation Operation - Turn Signal System OPERATION - TURN SIGNAL SYSTEM Lane change signaling is actuated by applying partial turn signal stalk movement toward the direction desired until the indicator lamps flashes in the instrument cluster. When the switch stalk is released the stalk will spring back into the neutral position turning OFF the turn signal. With the ignition switch ON and the turn signal switch stalk actuated left or right, current flows through the: - Multi-function switch - Body Control Module - Integrated Power Module (IPM) - Turn indicator lamp - Front and rear turn signal bulbs. A chime will sound after the vehicle has traveled a distance of approximately 1.0 mile and a speed of 15 mph, with the turn signal ON. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal Combination Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove upper and lower steering column shrouds. 3. Disconnect wire connector from back of multi-function switch. 4. Remove screws holding multi-function switch to steering column adapter collar. 5. Remove the multi-function switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Removal > Page 10294 Combination Switch: Service and Repair Installation INSTALLATION 1. Position the switch on to the steering column. 2. Install the two retaining screws. 3. Connect the wire harness connector. 4. Install the upper and lower steering column shrouds. 5. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Right B Pillar Left B Pillar Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 10298 Driver Door Passenger Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 10299 Right Sliding Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 10300 Liftgate Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 10301 Door Switch: Diagrams Hood Ajar Switch (Export) Left Front Ajar Switch (Base) Left Front Door Lock Motor/Ajar Switch (Except Base) Right Front Door Switch Ajar Switch (Base) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 10302 Right Front Door Lock Motor/Ajar Switch (Except Base) Right Sliding Door Lock Motor/Ajar Switch (Manual Sliding Door) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 10306 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 10307 Right Side Instrument Panel Lower RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 10308 Headlamp Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Connector Views Tail Lamp: Connector Views Left Rear Lamp Assembly Right Rear Lamp Assembly Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations Combination Switch: Locations Instrumental Panel Harness LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 10317 Left Side Instrument Panel LHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 10318 Steering Column Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 10319 Center Instrument Panel Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 10320 Steering Column Connectors RHD Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 10321 Multi-Function Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Description - Turn Signal System Combination Switch: Description and Operation Description - Turn Signal System DESCRIPTION - TURN SIGNAL SYSTEM The turn signals are actuated with a lever on Multi-Function Switch, located on the left side of the steering wheel. The signals are automatically turned off by a canceling cam (two lobes molded to the clock spring mechanism). The cam comes in contact with the cancel actuator on the turn signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns the switch to the OFF position. The multi-function switch is a resistive MUX switch that feeds inputs to the BCM. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Description - Turn Signal System > Page 10324 Combination Switch: Description and Operation Operation - Turn Signal System OPERATION - TURN SIGNAL SYSTEM Lane change signaling is actuated by applying partial turn signal stalk movement toward the direction desired until the indicator lamps flashes in the instrument cluster. When the switch stalk is released the stalk will spring back into the neutral position turning OFF the turn signal. With the ignition switch ON and the turn signal switch stalk actuated left or right, current flows through the: - Multi-function switch - Body Control Module - Integrated Power Module (IPM) - Turn indicator lamp - Front and rear turn signal bulbs. A chime will sound after the vehicle has traveled a distance of approximately 1.0 mile and a speed of 15 mph, with the turn signal ON. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair > Removal Combination Switch: Service and Repair Removal REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove upper and lower steering column shrouds. 3. Disconnect wire connector from back of multi-function switch. 4. Remove screws holding multi-function switch to steering column adapter collar. 5. Remove the multi-function switch. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair > Removal > Page 10327 Combination Switch: Service and Repair Installation INSTALLATION 1. Position the switch on to the steering column. 2. Install the two retaining screws. 3. Connect the wire harness connector. 4. Install the upper and lower steering column shrouds. 5. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams Turn Signal Lamp: Diagrams Left Front Park/Turn Signal Lamp Left Turn Signal Lamp (Export) Left Rear Lamp Assembly Right Front Park/Turn Signal Lamp Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Page 10331 Right Rear Lamp Assembly Right Turn Signal Lamp (Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Description and Operation Turn Signal Relay: Description and Operation The turn signal flasher function is incorperated into the Body Control Module (BCM), for further information, refer to Body Control Module for wiring diagrams and Powertrain Management/ Computers and Control Systems/ System Diagnosis/ Diagnostic Trouble Code Tests and Associated Procedures/ Manufacturer Code Charts/ Exterior Lighting. See: Body and Frame/Body Control Systems/Body Control Module See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code Charts/Exterior Lighting Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams Vanity Lamp: Diagrams Left Visor/Vanity Lamp (Premium/Luxury Except Export) Right Visor/Vanity Lamp (Except Base/Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions Heated Glass Element: Diagram Information and Instructions Warnings WARNINGS WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. - ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION. - USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE. - BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. - SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL. - OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA. - KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS. - TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER AND MUFFLER. - DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. - ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING. How to Find Wiring Diagrams Diagrams are presented in three main categories: ^ Power Distribution Diagrams Circuits feeding/protecting the system diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10343 ^ System Diagrams Component Circuits that work together as a system ^ Grounds Diagrams Circuits grounding the system diagrams Power Distribution Diagrams The power distribution diagrams are located at Power and Ground Distribution. These diagrams are especially useful for identifying potential suspects that could be causing any "dead/unpowered" fuses and/or for identifying potential suspects that could be the causing any "blown" fuses. System Diagrams These diagrams are useful for identifying a component's power source and its direct relationship to the other components in the same system. These diagrams may also indicate a component's indirect relationship with components in other systems. Grounds Diagrams The grounds diagrams are located at Power and Ground Distribution. These diagrams are useful for determining the interconnections of the grounding circuits of different systems. PLEASE NOTE: When locating diagrams by their ID numbers, some diagram sheets may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Navigate Between Wiring Diagrams Circuits that go from one diagram sheet to another will be marked with references indicating which diagram sheet the circuit went to/came from, i.e. "8W-16-4". Theses references will be in the form of unique diagram identification numbers (i.e. 8W-16-4, 8W-25-2, etc). All diagram sheets are identified with this unique ID number in their captions. Diagrams sheets being referred to that may reside outside of the set of diagrams you are viewing can be accessed by clicking on the hyperlink for "Diagrams By Number" which is provided with all sets of diagrams. PLEASE NOTE: When locating diagrams by their ID numbers, some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. How to Use Wiring Diagrams Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10344 Figure 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10345 Figure 2 DIAGRAM LAYOUT DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the sheet, and the ground (B-) side of the circuit is placed near the bottom of the sheet (Fig. 1). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10346 All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2). Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the sheet where the component is shown complete. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. The wiring diagrams are grouped into individual sets at the applicable system level. If a component is most likely found in a particular system, it will be shown complete (all wires, connectors, and pins) within that system's diagrams. It can, however, be shown partially in another system's diagrams if it contains some associated wiring. SYMBOLS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10347 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). CIRCUIT FUNCTIONS Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10348 Circuit Identification Code Chart All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. CIRCUIT INFORMATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10349 Fig.4 Wire Code Identification Wire Color Code Chart Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4). TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive AT .................................................................................................. ................................................................... Automatic Transmissions-Rear Wheel Drive MT ............. ........................................................................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC ................................................................................ ..................................................................................................... Single Over Head Cam Engine DOHC .................................................................................................................................................. ................................. Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Connector Views Information Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10350 Connector views show the connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram sheets, and a master list can be found at Vehicle/Diagrams. Connector, Ground and Splice Identification and Location CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. Identification Connectors, grounds, and splices are identified as follows: In-line connectors located in the engine compartment are C100 series numbers - In-line connectors located in the Instrument Panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. Locations Vehicle/Locations contains the master connector/ground/splice location index charts with hyperlinks to the applicable location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. The abbreviation T/O is used in the location column to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations. PLEASE NOTE: The master location index charts contain numerous items that may not be applicable to all vehicle models. If a link on the master location index chart to a figure is not functional, that means that the chart item and/or figure in question does NOT apply to the vehicle model selected. Connector Replacement REMOVAL 1. Disconnect battery Fig.10 Removal Of Dress Cover 2. Release Connector Lock (Fig. 10). 3. Disconnect the connector being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (Fig. 10). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10351 Fig.11 Examples Of Connector Secondary Terminal Locks 5. Release the Secondary Terminal Lock, if required (Fig. 11). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10352 Fig.12 Terminal Removal 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector (Fig. 12). INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Diode Replacement REMOVAL Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10353 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. Fig.13 Diode Identification 3. Remove the diode from the harness, pay attention to the current flow direction (Fig. 13). INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow (Fig. 13). 3. Solder the connection together using rosin core type solder only Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Terminal Replacement REMOVAL 1. Follow steps for removing terminals described in Connector Replacement. 2. Cut the wire 6 inches from the back of the connector. INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10354 Fig.14 Splice Band 3. Place the strands of wire overlapping each other inside of the splice clip. Fig.15 Crimping Tool 4. Using crimping tool, Mopar p/n 05019912AA, crimp the splice clip and wires together. Fig.16 Solder Splice 5. Solder the connection together using rosin core type solder only. CAUTION: DO NOT USE ACID CORE SOLDER. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10355 Fig.17 Heat Shrink Tube 6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. Special Tools Probing Tool Package 6807 Terminal Pick Tool Set 6680 Terminal Removing Tools 6932 And 8638 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10356 Terminal Removing Tool 6934 Splice Diagrams The splice diagram sheets (identified with an 8W-70 prefix) in Power and Ground Distribution contain splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. These diagram sheets show the entire splice and provide references to other system diagrams the splices serve. To find any diagram sheets referred to by number only, go to Vehicle/Diagrams/Electrical/Diagrams By Number. Symbols Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10357 Fig.3 Wiring Diagram Symbols International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world (Fig. 3). Terminology This is a list of terms and definitions used in the wiring diagrams. LHD ..................................................................................................................................................... .......................................... Left Hand Drive Vehicles RHD ................................................................. ............................................................................................................................ Right Hand Drive Vehicles ATX ....................................................................................................................................... .......................... Automatic Transmissions-Front Wheel Drive MTX ................................................... .................................................................................................................. Manual Transmissions-Front Wheel Drive Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10358 AT ........................................................................................................................................................ ............. Automatic Transmissions-Rear Wheel Drive MT ................................................................... ..................................................................................................... Manual Transmissions-Rear Wheel Drive SOHC .............................................................................................................................. ....................................................... Single Over Head Cam Engine DOHC ........................................ ........................................................................................................................................... Double Over Head Cam Engine Built-Up-Export .................................................................................................................. Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export ........................................................................................................................................ Vehicles Built For Sale In North America Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10359 Heated Glass Element: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices Fig.6 Electrostatic Discharge Symbol All ESD sensitive components are solid state and an Electrostatic Discharge Symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part form it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Intermittent and Poor Connections Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation. Troubleshooting Tests Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10360 Fig.7 Testing For Voltage Potential STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground (Fig. 7). 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. STANDARD PROCEDURE - TESTING FOR CONTINUITY 1. Remove the fuse for the circuit being checked or, disconnect the battery. Fig.8 Testing For Continuity 2. Connect one lead of the ohmmeter to one side of the circuit being tested (Fig. 8). 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10361 Fig.9 Testing For Voltage Drop STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Tools When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. Fig.5 Probing Tool Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10362 - Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe. Troubleshooting Wiring Problems When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10363 Heated Glass Element: Electrical Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. 8w-48-2 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 10364 8w-48-3 Other Diagram: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number. See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Page 10365 Heated Glass Element: Description and Operation The defroster button located on the HVAC control controls the rear window defogger and the heated side view mirrors. When the defroster button is pushed, the HVAC control sends a bus message over the PCI bus to the Front Control Module (FCM) which controls the Rear Window Defogger relay. The defroster LED will illuminate when the defroster function is on. The defroster will function for 10 minutes or can be cycled off sooner by pressing the defroster button again. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Page 10366 Heated Glass Element: Service and Repair GRID LINE AND TERMINAL REPAIR WARNING: MATERIALS CONTAINED IN THE REPAIR KIT (PART NUMBER 04549275) MAY CAUSE SKIN OR EYE IRRITATION. THE KIT CONTAINS EPOXY RESIN AND AMINE TYPE HARDENER, WHICH ARE HARMFUL IF SWALLOWED. AVOID CONTACT WITH THE SKIN AND EYES. FOR SKIN CONTACT, WASH THE AFFECTED AREAS WITH SOAP AND WATER. FOR CONTACT WITH THE EYES, FLUSH WITH PLENTY OF WATER. DO NOT TAKE INTERNALLY. IF TAKEN INTERNALLY, INDUCE VOMITING AND CALL A PHYSICIAN IMMEDIATELY. USE WITH ADEQUATE VENTILATION. DO NOT USE NEAR FIRE OR FLAME. CONTAINS FLAMMABLE SOLVENTS. KEEP OUT OF THE REACH OF CHILDREN. FAILURE TO FOLLOW THE WARNINGS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. Repair of the rear glass heating grid lines, bus bars or terminals can be accomplished using the Mopart Rear Window Defogger Repair Kit (Part Number 04549275) or equivalent. Grid Line Repair 1. Mask the repair area with masking tape so that the conductive epoxy can be applied neatly. Extend the epoxy application onto the grid line or the bus bar on each side of the break. 2. Follow the instructions in the repair kit for preparing the damaged area. 3. Remove the package separator clamp and mix the two conductive epoxy components thoroughly within the packaging. Fold the package in half and cut the center corner to dispense the epoxy. 4. For grid line repairs, mask the area to be repaired with masking tape or use a template. 5. Apply the epoxy through the slit in the masking tape or template. Overlap both ends of the break by at least 19 millimeters (0.75 inch). 6. For a terminal replacement, mask the adjacent areas so the epoxy can be extended onto the adjacent grid line as well as the bus bar. Apply a thin layer of epoxy to the area where the terminal was fastened and onto the adjacent grid line. 7. Apply a thin layer of conductive epoxy to the terminal and place it in the proper location on the bus bar. To prevent the terminal from moving while the epoxy is curing, it must be wedged or clamped. 8. Carefully remove the masking tape or template. CAUTION: Do not allow the glass surface to exceed 204° C (400° F) when using a heat gun, or the glass may fracture. 9. Allow the epoxy to cure 24 hours at room temperature, or carefully use a heat gun for fifteen minutes. When using a heat gun, hold it approximately 25.4 centimeters (10 inches) from the repair and do not allow the glass surface to exceed 204° C (400° F). NOTE: Do not attach the wire harness connectors to the terminals until the curing process is complete. 10. After the conductive epoxy is properly cured, remove the wedge or clamp from the terminal. 11. Connect the wire harness leads to the grid terminals and verify EBL operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Relay > Component Information > Locations > Page 10371 Rear Defogger Relay: Description and Operation Rear Window Defogger (EBL) Relay The rear window defogger (EBL) relay is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns. The EBL relay is a electromechanical device that switches battery current through a fuse in the integrated power module (IPM) to the rear window defogger grid and switches battery current through a positive thermal coefficient (PTC) in the IPM to the outside mirror heating grids. The EBL relay is energized when the relay coil is provided a ground path by the control circuitry within the front control module (FCM). The ISO-standard rear window defogger (EBL) relay is an electromechanical switch that uses a low current input controlled by the front control module (FCM) to control the high current output to the rear window defogger grid lines. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the rear window defogger grid lines. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The EBL relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard relay and for complete rear window defogger (EBL) wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Relay > Component Information > Locations > Page 10372 Rear Defogger Relay: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. Rear Window Defogger (EBL) Relay 2. Remove the cover from the integrated power module (IPM) located in the engine compartment. NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for EBL relay location. 3. Remove the EBL relay from the IPM. INSTALLATION NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for EBL relay location. 1. Position the EBL relay into the proper receptacle of the integrated power module (IPM). 2. Align the EBL relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Rear Defogger > Rear Defogger Switch > Component Information > Description and Operation Rear Defogger Switch: Description and Operation A/C Heater Control - Typical The switch for the rear window defogger (EBL) system is integrated into the A/C-heater control, which is located in the center of the instrument panel. When the rear window defogger switch is activated, the A/C-heater control requests the front control module (FCM) to operate the rear window defogger (EBL) relay. When the EBL relay is activated, current is directed to the rear defogger grid lines and the heated side view mirrors (if equipped). The grid lines heat the glass to help clear the surface of fog or frost. An LED indicator will illuminate when the rear window defogger switch is activated. When the switch is activated, the A/C-heater control requests the front control module (FCM) to operate the rear window defogger (EBL) relay. The EBL relay controls the current flow to the grids of the rear window defogger and to the heated side view mirrors, when equipped. NOTE: The EBL system turns off automatically after 10 minutes of initial operation. Each following activation cycle of the EBL system will last five minutes. The EBL system will initially be on for approximately ten minutes or until the rear window defogger switch or the ignition switch is turned off. After the initial time interval has expired, if the defogger switch is turned On again during the same ignition cycle, the EBL system will automatically turn off after about five minutes. The rear window defogger switch and the rear window defogger LED indicator cannot be repaired and, if faulty or damaged, the A/C-heater control must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 10380 Rear Defogger Relay: Description and Operation Rear Window Defogger (EBL) Relay The rear window defogger (EBL) relay is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns. The EBL relay is a electromechanical device that switches battery current through a fuse in the integrated power module (IPM) to the rear window defogger grid and switches battery current through a positive thermal coefficient (PTC) in the IPM to the outside mirror heating grids. The EBL relay is energized when the relay coil is provided a ground path by the control circuitry within the front control module (FCM). The ISO-standard rear window defogger (EBL) relay is an electromechanical switch that uses a low current input controlled by the front control module (FCM) to control the high current output to the rear window defogger grid lines. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the rear window defogger grid lines. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The EBL relay cannot be repaired and, if faulty or damaged, it must be replaced. Refer to the appropriate wiring information for diagnosis and testing of the ISO-standard relay and for complete rear window defogger (EBL) wiring diagrams. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Rear Defogger Relay > Component Information > Locations > Page 10381 Rear Defogger Relay: Service and Repair REMOVAL 1. Disconnect and isolate the negative battery cable. Rear Window Defogger (EBL) Relay 2. Remove the cover from the integrated power module (IPM) located in the engine compartment. NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for EBL relay location. 3. Remove the EBL relay from the IPM. INSTALLATION NOTE: Refer to the fuse and relay layout map on the inside of the IPM cover for EBL relay location. 1. Position the EBL relay into the proper receptacle of the integrated power module (IPM). 2. Align the EBL relay terminals with the terminal cavities in the IPM receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the cover onto the IPM. 4. Reconnect the negative battery cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Rear Defogger Switch > Component Information > Description and Operation Rear Defogger Switch: Description and Operation A/C Heater Control - Typical The switch for the rear window defogger (EBL) system is integrated into the A/C-heater control, which is located in the center of the instrument panel. When the rear window defogger switch is activated, the A/C-heater control requests the front control module (FCM) to operate the rear window defogger (EBL) relay. When the EBL relay is activated, current is directed to the rear defogger grid lines and the heated side view mirrors (if equipped). The grid lines heat the glass to help clear the surface of fog or frost. An LED indicator will illuminate when the rear window defogger switch is activated. When the switch is activated, the A/C-heater control requests the front control module (FCM) to operate the rear window defogger (EBL) relay. The EBL relay controls the current flow to the grids of the rear window defogger and to the heated side view mirrors, when equipped. NOTE: The EBL system turns off automatically after 10 minutes of initial operation. Each following activation cycle of the EBL system will last five minutes. The EBL system will initially be on for approximately ten minutes or until the rear window defogger switch or the ignition switch is turned off. After the initial time interval has expired, if the defogger switch is turned On again during the same ignition cycle, the EBL system will automatically turn off after about five minutes. The rear window defogger switch and the rear window defogger LED indicator cannot be repaired and, if faulty or damaged, the A/C-heater control must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations Passenger Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 10389 Power Window Switch: Diagrams Driver Power Window Switch (LHD Except Low Line) Driver Power Window Switch (LHD Low Line) Driver Power Window Switch (RHD) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 10390 Passenger Power Window Switch Power Window Switch (LHD Lowline) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 10391 Power Window Switch: Testing and Inspection 1. Remove the desired switch to be tested from the door trim panel. Driver's side (master) or passenger side. Power Window Master Switch Connector 2. Using an ohmmeter, Test driver door switch for continuity as described. Power Window Master Switch Test 3. If the result are not OK, replace the driver side window lift switch. * MUST TEST WITH B+ ON PIN 9 AND GROUND ON PIN 13 FOR CONTINUITY BETWEEN PINS 11 AND 6 Passenger Door Power Window Switch 4. Test passenger door switch for continuity as described. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 10392 Passenger Window Switch Test 5. If the results are not OK, replace the switch. The power window master switch has a Auto-Down feature. The switch is equipped with two detent positions when actuating the power window OPEN. The first detent position allows the window to roll down and stop when the switch is released. The second detent position actuates an integral express roll down relay that rolls the window down after the switch is released. When the express down circuit senses stall current (window has reached end of down travel), the switch will turn current off to the motor. The AUTO feature can be cancelled by actuating the switch UP or DOWN while window is in motion. If the electronic circuit in the switch fails to detect a stall current, the auto down circuit will time out within 9 to 13 seconds. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Page 10393 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Window Switch 2. Using a trim stick, start at the bottom of the switch and bezel assembly and pry up to remove the switch and bezel assembly from the door trim panel. 3. Unlatch the locking tab on the harness side connector of the switch. 4. Disconnect wire harness connectors from switch. INSTALLATION 1. Reconnect wire harness connector to switch. 2. Insert switch into door trim panel and press into place. 3. Reconnect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams Power Seat Circuit Breaker (25A) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Service and Repair Front Door Window Motor: Service and Repair REMOVAL The window motor is incorporated into the window regulator assembly. If the window motor requires replacement, the window regulator must be replaced. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Quarter Window Motor > Component Information > Service and Repair Quarter Window Motor: Service and Repair REMOVAL 1. Disconnect cable. 2. Remove D-pillar trim panel. 3. Disconnect wire connector from power vent motor. 4. Using a flat bladed tool, carefully lift the circular actuator link tab. Remove link from window ball socket. Vent Window Motor 5. Remove bolts holding power vent motor to D-pillar. 6. Remove power vent motor. INSTALLATION 1. Obtain new vent window motor. 2. Snap the actuator link socket onto the quarter window ball socket. Using a soft rubber mallet, push the circular link tab flush with link surface. 3. Install bolts holding power vent motor to D-pillar. 4. Reconnect wire connector to power vent motor. 5. Reconnect the battery negative cable. 6. Cycle quarter window open/close to verify function. 7. Install D-pillar trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations Passenger Door Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 10408 Power Window Switch: Diagrams Driver Power Window Switch (LHD Except Low Line) Driver Power Window Switch (LHD Low Line) Driver Power Window Switch (RHD) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 10409 Passenger Power Window Switch Power Window Switch (LHD Lowline) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 10410 Power Window Switch: Testing and Inspection 1. Remove the desired switch to be tested from the door trim panel. Driver's side (master) or passenger side. Power Window Master Switch Connector 2. Using an ohmmeter, Test driver door switch for continuity as described. Power Window Master Switch Test 3. If the result are not OK, replace the driver side window lift switch. * MUST TEST WITH B+ ON PIN 9 AND GROUND ON PIN 13 FOR CONTINUITY BETWEEN PINS 11 AND 6 Passenger Door Power Window Switch 4. Test passenger door switch for continuity as described. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 10411 Passenger Window Switch Test 5. If the results are not OK, replace the switch. The power window master switch has a Auto-Down feature. The switch is equipped with two detent positions when actuating the power window OPEN. The first detent position allows the window to roll down and stop when the switch is released. The second detent position actuates an integral express roll down relay that rolls the window down after the switch is released. When the express down circuit senses stall current (window has reached end of down travel), the switch will turn current off to the motor. The AUTO feature can be cancelled by actuating the switch UP or DOWN while window is in motion. If the electronic circuit in the switch fails to detect a stall current, the auto down circuit will time out within 9 to 13 seconds. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Page 10412 Power Window Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. Power Window Switch 2. Using a trim stick, start at the bottom of the switch and bezel assembly and pry up to remove the switch and bezel assembly from the door trim panel. 3. Unlatch the locking tab on the harness side connector of the switch. 4. Disconnect wire harness connectors from switch. INSTALLATION 1. Reconnect wire harness connector to switch. 2. Insert switch into door trim panel and press into place. 3. Reconnect battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding Front Door Window Glass Weatherstrip: Service and Repair Front Door Outer Belt Molding FRONT DOOR OUTER BELT MOLDING REMOVAL 1. Remove the side view mirror. 2. Remove door trim panel. 3. Roll door glass down. Fig. 1 4. Using a hook tool, disengage interlocking lip at the base of the inward edge of the belt molding (Fig. 1). 5. Remove belt molding from door. INSTALLATION 1. Place belt molding in position on door (Fig. 1). NOTE: Make sure end of applique is against outer belt. 2. Engage interlocking lip at the base of the inward edge of the belt molding on door panel. 3. Install door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 10419 Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip FRONT DOOR GLASS RUN WEATHERSTRIP REMOVAL 1. Remove door frame closeout moldings. 2. Pull weatherstrip from glass run channel at rear of door frame, working from the bottom to the top. 3. Disengage clip attaching weatherstrip to door frame. Fig. 1 4. Pull weatherstrip from lip along top of door frame (Fig. 1). 5. Remove door trim panel. 6. Remove door speaker, if equipped. 7. Remove watershed as necessary to gain access to screw attaching front lower corner of glass run weatherstrip to inner door panel. 8. Remove screw attaching glass run weatherstrip to inner door panel. 9. Remove inner belt weatherstrip. 10. Pull weatherstrip from front glass run channel. 11. Remove glass run weatherstrip from vehicle. INSTALLATION 1. Position glass run weatherstrip on vehicle (Fig.1). 2. Insert A-pillar section of the glass run into door through belt line and lower to bottom of door using molded corners as a guide. NOTE: Care must be taken not to damage the medal bracket when installing through the belt opening. 3. Locate the top corner portion of the B-pillar glass run section onto the roll frame and slide it up until the part bottoms out on the header portion of the roll frame. NOTE: Do not JAM the corner into place. 4. Install the entire B-pillar glass run onto roll frame. 5. Working from the B-pillar forward install the first eight to twelve inches of the header glass run onto the roll frame. NOTE: Use care not to push or pull the header section and the molded corner out of location. 6. Install fully the entire A-pillar glass run section by indexing the molded corner detail into the roll frame. Slide the glass run up the A-pillar until Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 10420 the rubber molded joint just touches the roll frame. 7. Verify that the tertiary seal is on the correct side of the roll frame prior to seating the glass run fully onto the frame. Verify the glass runs is fully seated for the header, and A-pillar and B-pillar 8. Install screw attaching glass run weatherstrip to inner door panel. 9. Install inner belt weatherstrip. 10. Install watershed. 11. Push weatherstrip groove onto lip along top of door frame. 12. Engage clip into slot in door frame. 13. Push weatherstrip into channel at rear of door frame, working from the top to bottom. 14. Install door frame closeout moldings. 15. Install door speaker, if equipped. 16. Install door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Outer Belt Molding > Page 10421 Front Door Window Glass Weatherstrip: Service and Repair Front Door Inner Belt Molding FRONT DOOR INNER BELT MOLDING REMOVAL 1. Remove door trim panel. 2. Peel upper corner seals away form inner belt molding to clear removal path. Fig. 1 3. Pull inner belt molding upward to disengage retaining channel in bottom of molding from door panel flange (Fig. 1). 4. Remove inner belt molding from vehicle. INSTALLATION 1. Place inner belt molding in position on door (Fig. 1). 2. Push inner belt molding downward to engage retaining channel onto door panel flange. 3. Install upper corner seals in proper location. 4. Install door trim panel. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair Liftgate Window Glass: Service and Repair LIFTGATE GLASS REMOVAL Refer to the Service Precautions for description of tools and adhesive systems that are recommended for use in this procedure. REAR WINDOW REMOVAL - EXTERIOR METHOD 1. Remove rear window wiper arm. 2. Remove interior trim covers. 3. Disconnect wires for electrically heated window, if equipped. Fig. 1 4. Using a sharp cold knife, cut urethane adhesive attaching the rear window to the liftgate. A power cutting device can be used if available (Fig. 1). 5. Remove rear window from vehicle. INSTALLATION Refer to the Service Precautions for description of tools and adhesive systems that are recommended for use in this procedure. CAUTION: Open the left front door glass before installing rear window to avoid pressurizing the passenger compartment. If a door is slammed before urethane bonding is cured, water leaks can result. Allow the urethane at least 24 hours to cure before returning the vehicle to use. To avoid stressing the replacement rear window,the urethane bonding material on the rear window fence should be smooth and consistent to the shape of the replacement glass. 1. Place replacement glass into rear window opening. 2. Verify the glass lays evenly against the pinch weld fence at the sides, top and bottom of the replacement rear window. If not, the urethane adhesive remaining on the fence must be formed to the shape of the new glass. 3. Using a grease pencil, mark the glass and lift-gate in several locations to aid installation. 4. Remove replacement glass from liftgate opening. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Page 10425 Fig. 2 5. Position the rear window inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed parallel 75 cm (2.5 ft.) apart (Fig. 2). WARNING: DO NOT USE SOLVENT BASED GLASS CLEANER TO CLEAN REAR WINDOW BEFORE APPLYING GLASS PREP AND PRIMER. POOR ADHESION CAN RESULT. 6. Clean inside of rear window with ammonia based glass cleaner and lint-free cloth. 7. Apply Glass Prep adhesion promoter 25 mm (1 in.) wide around perimeter of rear window and wipe with clean/dry lint-free cloth until no streaks are visible. 8. Apply Glass Primer 25 mm (1 in.) wide around perimeter of rear window. Allow at least three minutes drying time. 9. Apply Pinch weld Primer 19 mm (0.75 in.) wide around the rear window fence. Allow at least three minutes drying time. 10. If a low viscosity urethane adhesive is used, install compression spacers on the fence around the rear window opening. 11. Apply a 10 mm (0.4 in.) bead of urethane along center line of rear window fence. CAUTION: Be careful so that spacers do not contaminate urethane bead. 12. Apply 2 glass spacer clips to bottom edge of glass, approximately 150 mm (6.0 inches) inboard from each corner. 13. With the aid of a helper, position the rear window over the rear window opening and align the reference marks. 14. Slowly lower glass to rear window opening fence. Ensure spacers on bottom edge of glass contact sheet metal ledge. Then, push glass inward until flush to liftgate surface. 15. Clean excess urethane from exterior with Mopar(R) Super Kleen, or equivalent. 16. Apply 150 mm (6 in.) lengths of 50 mm (2 in.) masking tape spaced 250 mm (10 in.) apart to hold molding in place until urethane cures. 17. Install rear window wiper arm. 18. Install interior trim. 19. After urethane has cured, remove tape strips, slide out bottom spacer clips, and then water test rear window to verify repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair Quarter Window Glass: Service and Repair QUARTER WINDOW REMOVAL 1. Remove C-pillar trim. 2. Open quarter glass to vent position. 3. Disengage quarter window retainer from vent motor arm. Fig. 5 4. Remove nuts attaching quarter glass to C-pillar (Fig. 5). 5. Use magnetic socket to prevent dropping into the pillar. 6. Remove quarter glass from vehicle. INSTALLATION 1. Place quarter glass in position on vehicle. 2. Install nuts attaching quarter glass to C-pillar. 3. Engage quarter window retainer to vent motor arm. 4. Install screw attaching quarter window retainer to vent motor arm. 5. Close quarter glass. 6. Verify alignment and flushness. 7. Install C-pillar trim. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Sliding Door Window Glass > System Information > Service and Repair Sliding Door Window Glass: Service and Repair SLIDING DOOR GLASS REMOVAL The temperature of the vehicle should be at least 21 degrees C (70 degrees F) before removing the stationary quarter / sliding door glass. Butyl sealer becomes more pliable at high temperatures. 1. Remove interior trim as necessary to gain access attaching locations on back of glass. 2. Remove nuts holding stationary glass to fence. Fig. 4 3. Using razor knife, cut butyl sealer holding glass to fence from between the mounting studs (Fig. 4). 4. Push glass from opening. INSTALLATION The temperature of the vehicle should be at least 21 degrees C (70 degrees F) before removing the stationary quarter / sliding door glass. Butyl sealer becomes more pliable at high temperatures. The stationary glass fence should be cleaned of all old butyl sealer. 1. Apply a 6 mm (0.25 in.) butyl tape around perimeter of glass assembly encapsulation track. Ensure that the butyl tape is wrapped around the mounting studs. 2. Place the glass into the opening and insert mounting studs through holes in fence. 3. Install nuts to hold stationary glass to fence. CAUTION: Tighten nuts to 3.4 N.m (30 in.lbs.) torque in the sequence indicated. Do not over torque, or glass breakage may result (Fig. 4). 4. Water test before installing interior trim. 5. Install interior trim. 6. Verify alignment and flushness. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Handle > Component Information > Service and Repair > Procedures Window Handle: Procedures REMOVAL Window Crank - Typical 1. Using a window crank removal tool, disengage clip attaching window crank to regulator shaft. NOTE: Wrap a shop towel around the window crank to catch the clip when it springs out. 2. Pull window crank from regulator shaft. INSTALLATION 1. Place the clip on to the window crank handle. 2. Position window crank to regulator shaft. 3. Push window crank onto regulator shaft to engage retaining clip. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Handle > Component Information > Service and Repair > Procedures > Page 10436 Window Handle: Removal and Replacement WINDOW CRANK REMOVAL Fig. 23 1. Using a window crank removal tool, disengage clip attaching window crank to regulator shaft (Fig. 23). NOTE: Wrap a shop towel around the window crank to catch the clip when it springs out. 2. Pull window crank from regulator shaft. INSTALLATION 1. Place the clip on to the window crank handle. 2. Position window crank to regulator shaft. 3. Push window crank onto regulator shaft to engage retaining clip. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Manual Front Door Window Regulator: Service and Repair Manual REMOVAL 1. Remove watershield. 2. Remove inner belt molding. 3. Remove door glass. Front Door Manual Window 4. Loosen screws attaching front and rear window guide rails to inner door panel. 5. Remove screw heads on guide rails from key hole slots in inner door panel. 6. Loosen screws attaching regulator to inner door panel. 7. Remove regulator from inner door panel. 8. Extract rear guide rail through inner door panel rear access hole. 9. Extract front guide rail through front access hole. INSTALLATION Front Door Manual Window Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Manual > Page 10442 1. Insert front guide rail through front access hole. 2. Insert rear guide rail through rear access hole. 3. Place window regulator in position on inner door panel. 4. Place screw heads on guide rails in position through key hole slots in inner door panel. 5. Tighten screws to attach front and rear guide rails to inner door panel to 8.5 -1 0.7 Nm (75 -9 5 in. IDS.). Tighten using the sequence. 6. Tighten screws to attach regulator to inner door panel to 2.8 Nm (25 in. IDS.). 7. Install door glass. 8. Verify door glass alignment and operation. 9. Install inner belt molding. 10. Install watershield. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Manual > Page 10443 Front Door Window Regulator: Service and Repair Power REMOVAL 1. Remove watershield. 2. Remove inner belt molding. 3. Remove door glass. 4. Disconnect wire connector from power window motor. Front Door Power Window 5. Loosen screws attaching front and rear window guide rails to inner door panel. 6. Remove screw heads on guide rails from key hole slots in inner door panel. 7. Loosen screws attaching motor/housing to inner door panel. Front Door Power Window 8. Remove regulator from inner door panel. 9. Extract rear guide rail through inner door panel rear access hole. 10. Extract front guide rail through front access hole. INSTALLATION Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Manual > Page 10444 Front Door Power Window 1. Insert front guide rail through front access hole. 2. Insert rear guide rail through rear access hole. 3. Place window regulator in position on inner door panel. 4. Place screw heads on guide rails in position through key hole slots in inner door panel. 5. Tighten screws to attach front and rear guide rails to inner door panel to 8.5 - 10.7 Nm (75 - 95 in. IDS.). Tighten using the sequence. Front Door Power Window 6. Tighten screws to attach motor/housing to inner door panel to 2.8 Nm (25 in. lbs.). 7. Connect wire connector into power window motor. 8. Install door glass. 9. Verify door glass alignment and operation. 10. Install inner belt molding. 11. Install watershield. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 23-047-05 > Oct > 05 > Body - Whistle Sound From Rear Quarter Glass Window Seal: Customer Interest Body - Whistle Sound From Rear Quarter Glass NUMBER: 23-047-05 GROUP: Body DATE: October 7, 2005 SUBJECT: Whistle Sound From Rear Quarter Glass Area OVERVIEW: This bulletin involves applying RTV sealant to the quarter glass weatherstrip vent holes. MODELS: 2005 - 2006 (RS) Town & Country, Caravan NOTE: This bulletin applies to long wheel base vehicles equipped with Power Vents (sales code JKG) built on or after April 1, 2005 (MDH 0401XX). SYMPTOM/CONDITION: Whistle sound from either rear quarter glass area. DIAGNOSIS: 1. Prepare the vehicle as follows: a. Close all windows including the rear quarter glass windows. b. Place the A/C Heater control in fresh air mode (not recirculation). c. Operate the heater blower motor at high speed. d. While sitting in the third row seat, listen for a whistling sound in the area of both rear quarter windows. 2. Is a whistling sound audible? a. Yes » go to Step # 3. b. No » this bulletin does not apply. Further diagnosis is necessary. 3. While the whistling noise is present, open the appropriate rear quarter glass window. 4. Is the whistling sound eliminated? a. Yes » perform the repair procedure on the appropriate side of the vehicle. b. No » this bulletin does not apply. Further diagnosis is necessary. PARTS REQUIRED REPAIR PROCEDURE: 1. Open the rear quarter window. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest for Window Seal: > 23-047-05 > Oct > 05 > Body - Whistle Sound From Rear Quarter Glass > Page 10453 2. Clean the appropriate weatherstrip with isopropyl alcohol in the area shown in (Fig. 1) 3. Locate a number of small holes in the rearward portion of the weatherstrip (Fig. 1). Apply a very small amount of RTV sealer on the tip of your finger, and fill each hole in the weatherstrip that you can feel (Fig. 1). NOTE: Be careful to remove any excess RTV from the weatherstrip. NOTE: Allow the RTV sealer to dry for 30 minutes before closing the quarter window. 4. Repeat Step # 1 through Step # 3. on the other side of the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE DISCLAIMER This bulletin is supplied as technical information only and is not as authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 23-047-05 > Oct > 05 > Body - Whistle Sound From Rear Quarter Glass Window Seal: All Technical Service Bulletins Body - Whistle Sound From Rear Quarter Glass NUMBER: 23-047-05 GROUP: Body DATE: October 7, 2005 SUBJECT: Whistle Sound From Rear Quarter Glass Area OVERVIEW: This bulletin involves applying RTV sealant to the quarter glass weatherstrip vent holes. MODELS: 2005 - 2006 (RS) Town & Country, Caravan NOTE: This bulletin applies to long wheel base vehicles equipped with Power Vents (sales code JKG) built on or after April 1, 2005 (MDH 0401XX). SYMPTOM/CONDITION: Whistle sound from either rear quarter glass area. DIAGNOSIS: 1. Prepare the vehicle as follows: a. Close all windows including the rear quarter glass windows. b. Place the A/C Heater control in fresh air mode (not recirculation). c. Operate the heater blower motor at high speed. d. While sitting in the third row seat, listen for a whistling sound in the area of both rear quarter windows. 2. Is a whistling sound audible? a. Yes » go to Step # 3. b. No » this bulletin does not apply. Further diagnosis is necessary. 3. While the whistling noise is present, open the appropriate rear quarter glass window. 4. Is the whistling sound eliminated? a. Yes » perform the repair procedure on the appropriate side of the vehicle. b. No » this bulletin does not apply. Further diagnosis is necessary. PARTS REQUIRED REPAIR PROCEDURE: 1. Open the rear quarter window. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Seal: > 23-047-05 > Oct > 05 > Body - Whistle Sound From Rear Quarter Glass > Page 10459 2. Clean the appropriate weatherstrip with isopropyl alcohol in the area shown in (Fig. 1) 3. Locate a number of small holes in the rearward portion of the weatherstrip (Fig. 1). Apply a very small amount of RTV sealer on the tip of your finger, and fill each hole in the weatherstrip that you can feel (Fig. 1). NOTE: Be careful to remove any excess RTV from the weatherstrip. NOTE: Allow the RTV sealer to dry for 30 minutes before closing the quarter window. 4. Repeat Step # 1 through Step # 3. on the other side of the vehicle. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE FAILURE CODE DISCLAIMER This bulletin is supplied as technical information only and is not as authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 23-035-05 > Jul > 05 > Body - Circular/Ring Marks on Glass Windshield: Customer Interest Body - Circular/Ring Marks on Glass NUMBER: 23-035-05 GROUP: Body DATE: July 26, 2005 SUBJECT: Circular/Ring Marks On Glass MODELS DISCUSSION: Circular patterns may appear on the glass which are visible mostly when the glass is moist or fogged up. The size varies from 2-6 inches and are typically described as "rings" or "circles" that won't clean off with standard glass cleaners. To determine if this type of mark(s) is present use a clean, moist cloth lightly wet the surface of the glass component. Carefully observe if these circular marks develop as the water from the cloth dissipates. Repeat this process on both the inside and outside of the glass component (if applicable) to identify which surface of glass (inside or outside) has the condition. If the marks are present on the outside of glass, this condition will naturally lessen with sunlight exposure and time. Customer concerns are mostly associated with this condition being present on the inside surface. If the customer wants the marks removed, they can be removed using a non-abrasive cleanser or polish. Appropriate materials are Calcium Carbonate (Bon Ami(R)) or a glass polish containing Cerium Oxide. CAUTION: Do not use any materials containing quartz or silicate abrasives. Typical examples of abrasive cleansers include (Ajax(R), Comet(R), Soft-Scrub(R), etc). Cleansers with abrasives will scratch the glass surface and cause irreparable damage. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 23-035-05 > Jul > 05 > Body - Circular/Ring Marks on Glass > Page 10468 PARTS REQUIRED CLEANING PROCEDURE: 1. Moisten a clean cloth with water. 2. Wipe the glass surface leaving a very fine film of water on the glass. 3. Observe the location of the marks on the glass. 4. If the marks are on the inside of the glass surface, take precautions to cover any of the interior components the cleanser could come in contact with. 5. Rinse the cloth with clean water. 6. Apply cleanser to the moist cloth. 7. Rub the surface of the glass with the cleanser in a circular pattern being sure to cover the entire area that the mark involves. 8. Wash off any residual cleanser material with a moist cloth. 9. Dry the glass surface. 10. Check that the removal has been successful by rubbing a moistened, clean cloth back over the cleaned surface and inspect for suction cup marks. 11. Repeat as necessary to remove all of the mark(s) from the glass surface(s). POLICY: Information Only Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 23-035-05 > Jul > 05 > Body - Circular/Ring Marks on Glass Windshield: All Technical Service Bulletins Body - Circular/Ring Marks on Glass NUMBER: 23-035-05 GROUP: Body DATE: July 26, 2005 SUBJECT: Circular/Ring Marks On Glass MODELS DISCUSSION: Circular patterns may appear on the glass which are visible mostly when the glass is moist or fogged up. The size varies from 2-6 inches and are typically described as "rings" or "circles" that won't clean off with standard glass cleaners. To determine if this type of mark(s) is present use a clean, moist cloth lightly wet the surface of the glass component. Carefully observe if these circular marks develop as the water from the cloth dissipates. Repeat this process on both the inside and outside of the glass component (if applicable) to identify which surface of glass (inside or outside) has the condition. If the marks are present on the outside of glass, this condition will naturally lessen with sunlight exposure and time. Customer concerns are mostly associated with this condition being present on the inside surface. If the customer wants the marks removed, they can be removed using a non-abrasive cleanser or polish. Appropriate materials are Calcium Carbonate (Bon Ami(R)) or a glass polish containing Cerium Oxide. CAUTION: Do not use any materials containing quartz or silicate abrasives. Typical examples of abrasive cleansers include (Ajax(R), Comet(R), Soft-Scrub(R), etc). Cleansers with abrasives will scratch the glass surface and cause irreparable damage. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 23-035-05 > Jul > 05 > Body - Circular/Ring Marks on Glass > Page 10474 PARTS REQUIRED CLEANING PROCEDURE: 1. Moisten a clean cloth with water. 2. Wipe the glass surface leaving a very fine film of water on the glass. 3. Observe the location of the marks on the glass. 4. If the marks are on the inside of the glass surface, take precautions to cover any of the interior components the cleanser could come in contact with. 5. Rinse the cloth with clean water. 6. Apply cleanser to the moist cloth. 7. Rub the surface of the glass with the cleanser in a circular pattern being sure to cover the entire area that the mark involves. 8. Wash off any residual cleanser material with a moist cloth. 9. Dry the glass surface. 10. Check that the removal has been successful by rubbing a moistened, clean cloth back over the cleaned surface and inspect for suction cup marks. 11. Repeat as necessary to remove all of the mark(s) from the glass surface(s). POLICY: Information Only Disclaimer This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 10475 Windshield: Service Precautions WARNING WINDSHIELD SAFETY PRECAUTIONS WARNING: DO NOT OPERATE THE VEHICLE WITHIN 24 HOURS OF WINDSHIELD INSTALLATION. IT TAKES AT LEAST 24 HOURS FOR URETHANE ADHESIVE TO CURE. IF IT IS NOT CURED, THE WINDSHIELD MAY NOT PERFORM PROPERLY IN AN ACCIDENT. URETHANE ADHESIVES ARE APPLIED AS A SYSTEM. USE GLASS CLEANER, GLASS PREP SOLVENT, GLASS PRIMER, PVC (VINYL) PRIMER AND PINCH WELD (FENCE) PRIMER PROVIDED BY THE ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL INTEGRITY COULD BE COMPROMISED. DAIMLERCHRYSLER DOES NOT RECOMMEND GLASS ADHESIVE BY BRAND. TECHNICIANS SHOULD REVIEW PRODUCT LABELS AND TECHNICAL DATA SHEETS, AND USE ONLY ADHESIVES THAT THEIR MANUFACTURES WARRANT WILL RESTORE A VEHICLE TO THE REQUIREMENTS OF FMVSS 212. TECHNICIANS SHOULD ALSO INSURE THAT PRIMERS AND CLEANERS ARE COMPATIBLE WITH THE PARTICULAR ADHESIVE USED. BE SURE TO REFER TO THE URETHANE MANUFACTURER'S DIRECTIONS FOR CURING TIME SPECIFICATIONS, AND DO NOT USE ADHESIVE AFTER ITS EXPIRATION DATE. VAPORS THAT ARE EMITTED FROM THE URETHANE ADHESIVE OR PRIMER COULD CAUSE PERSONAL INJURY. USE THEM IN A WELL-VENTILATED AREA. SKIN CONTACT WITH URETHANE ADHESIVE SHOULD BE AVOIDED. PERSONAL INJURY MAY RESULT. ALWAYS WEAR EYE AND HAND PROTECTION WHEN WORKING WITH GLASS. CAUTION: Protect all painted and trimmed surfaces from coming in contact with urethane or primers. Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 10476 Windshield: Service and Repair WINDSHIELD DESCRIPTION The windshield is attached to the window frame with urethane adhesive. The urethane adhesive is applied cold and seals the surface area between the window opening and the glass. The primer adheres the urethane adhesive to the windshield. It is difficult to salvage a windshield during the removal operation. The windshield is part of the structural support for the roof. The urethane bonding used to secure the windshield to the fence is difficult to cut or clean from any surface. If the moldings are set in urethane, it would also be unlikely they could be salvaged. Before removing the windshield, check the availability of the windshield and moldings from the parts supplier. REMOVAL WINDSHIELD REMOVAL - EXTERIOR METHOD The urethane adhesive holding the windshield to the opening pinch weld (fence) can be cut using a sharp cold knife from the exterior of the vehicle. Using the cold knife method is effective if the windshield is already broken. If the glass must be salvaged, cutting the urethane adhesive from the interior of the vehicle using a reciprocating or oscillating power knife is recommended. 1. Remove inside rear view mirror. 2. Remove windshield wiper arms. 3. Remove cowl cover. 4. Remove A-pillar trim panels. 5. Place protective covers over instrument panel and hood. 6. Remove windshield molding. Using pliers, pull outward on molding at the bottom of A-pillars. Fig. 1 7. Using a sharp cold knife, cut urethane adhesive holding the windshield to the A-pillars, roof header and cowl pinch weld fences (Fig. 1). A power cutting device can be used if available. 8. Remove windshield from vehicle. WINDSHIELD REMOVAL - INTERIOR METHOD 1. Remove inside rear view mirror. 2. Remove instrument panel top cover. 3. Remove A-pillar trim covers. 4. Place protective covers over instrument panel and hood. 5. Using a reciprocating or oscillating power knife, cut urethane adhesive holding the windshield to the A-pillars, roof header and cowl pinch weld fences. Refer to instructions provided with the equipment being used. 6. Remove windshield from vehicle. INSTALLATION The urethane adhesive holding the windshield to the opening pinch weld (fence) can be cut using a sharp cold knife from the exterior of the vehicle. Using the cold knife method is effective if the windshield is already broken. If the glass must be salvaged, cutting the urethane adhesive from the interior of the vehicle using a reciprocating or oscillating power knife is recommended. CAUTION: Open the left front door glass before installing windshield to avoid pressurizing the passenger compartment. If a door is slammed Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 10477 before urethane bonding is cured, water leaks can result. Allow the urethane at least 24 hours to cure before returning the vehicle to use. To avoid stressing the replacement windshield, the urethane bonding material on the windshield fence should be smooth and consistent to the shape of the replacement windshield. The support spacers should be cleaned and properly installed on weld studs or repair screws at bottom of windshield opening. 1. Place replacement windshield into windshield opening and position glass in the center of the opening against the compression spacers. 2. Verify the glass lays evenly against the pinch urethane adhesive remaining on the weld fence at the sides, top and bottom of the replacement windshield. If not, the pinch weld fence must be formed to the shape of the new glass. 3. Remove replacement windshield from windshield opening. Fig. 2 4. Position the windshield inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed parallel 75 cm (2.5 ft.) apart (Fig. 2). WARNING: DO NOT USE SOLVENT BASED GLASS CLEANER TO CLEAN WINDSHIELD BEFORE APPLYING GLASS PREP AND PRIMER. POOR ADHESION CAN RESULT. 5. Clean inside of windshield with ammonia based glass cleaner and lint-free cloth. 6. Install molding to perimeter of windshield. 7. Apply Glass Prep adhesion promoter 25 mm (1 in.) wide around perimeter of windshield and wipe with clean/dry lint-free cloth until no streaks are visible. 8. Apply Glass Primer 25 mm (1 in.) wide around perimeter of windshield. Allow at least three minutes drying time. 9. Using a razor knife, remove as much original urethane as possible. Do not damage paint on windshield fence. 10. Apply pinch weld primer 19 mm (0.75 in.) wide around the windshield fence. Allow at least three minutes drying time. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 10478 Fig. 3 11. If a low viscosity urethane adhesive is used, install compression spacers on the fence around the windshield opening (Fig. 3). 12. Apply a 10 mm (0.4 in.) bead of urethane on center line of windshield fence. 13. With the aid of a helper, position the windshield over the windshield opening. 14. Slowly lower windshield glass to windshield opening fence. Guide the molding into proper position as necessary. Push windshield inward until molding is flush to roof line and A-pillars (Fig. 3). 15. Clean access urethane from exterior with Mopar(R) Super Kleen or equivalent. 16. Apply 150 mm (6 in.) lengths of 50 mm (2 in.) masking tape spaced 250 mm (10 in.) apart to hold molding in place until urethane cures. 17. Install A-pillar trim panels. 18. Install cowl cover and wipers. 19. Install inside rear view mirror. 20. After urethane has cured, remove tape strips and water test windshield to verify repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Motor > Component Information > Locations Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Motor > Component Information > Locations > Page 10483 Headlamp Washer Pump Motor (Export) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Headlamp Washer Motor Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Headlamp Washer Motor Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Left Side Engine Compartment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10494 Wiper Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10495 Wiper Control Module: Service and Repair REMOVAL 1. Release the hood latch and open hood. 2. Disconnect and isolate the battery negative cable. 3. Remove the wiper arms. 4. Remove the cowl cover. Wiper Module Wire Connector 5. Disconnect the positive lock on the wiper module wire connector. 6. Disconnect the wiper module wire connector from the engine compartment wire harness. 7. Disconnect the windshield washer hose from coupling outside the module. 8. Disconnect the drain tubes from nipples on bottom of the wiper module. 9. Remove nuts holding wiper module to lower windshield fence. Wiper Module 10. Remove bolts holding the wiper module to the dash panel. 11. Lift wiper module from weld-studs on lower windshield fence. CAUTION: Do not allow wiper module to rest on brake master cylinder reservoir, damage to brake system can result. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10496 12. Remove wiper module. INSTALLATION NOTE:If replacing the wiper tub, the components must be transferred to the new tub. 1. Position the wiper module into the cowl. 2. Install the bolts that secure the wiper module to the dash (WIPER MODULE). Tighten bolts to 17 Nm (150 in. lbs.). 3. Install the nuts that retain the wiper module to the bulkhead fenceline. Tighten nuts to 7 Nm (62 in. lbs.). 4. Connect the drain tubes to the nipples on the wiper module. 5. Connect the windshield washer tube. 6. Connect the wire harness connector to the wiper module (WIPER MODULE). 7. Connect the positive lock on the wiper module wire connector (WIPER MODULE WIRE CONNECTOR). CAUTION: Do not allow wiper module to rest on brake master cylinder reservoir, damage to brake system can result. 8. Install the cowl cover. 9. Install the wiper arms and blades. Tighten nuts to 37 Nm (27 ft. lbs.). 10. Connect the battery negative cable. 11. Close the hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 10504 Washer Fluid Level Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 10505 Washer Fluid Level Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Hoist and support vehicle on hoist or jack stands. 3. If necessary, remove the right front wheel and tire assembly. 4. Disconnect the right front wheelhouse splash shield and move aside. 5. Drain washer fluid from the reservoir and into a suitable clean container. This can be done by disconnecting the windshield washer hose from the front (outboard) washer pump port allowing the washer fluid to drain into a container through a temporary jumper hose connected to the front washer pump. 6. Disconnect the electrical body harness connector to the the fluid level sensor. Slide the red lock on the connector to the release position, then, depress the black tab and pull the connector off the sensor. 7. Remove the sensor from reservoir by using a side foot to gently pry the sensor from the body of the reservoir. Do not damage the reservoir/sensor sealing surface or puncture reservoir during removal. CAUTION: To avoid damage to the sensor, assure the reservoir is in an upright position before removing the sensor from the reservoir. Do not rotate the sensor during removal. INSTALLATION 1. Use a new grommet when installing a new sensor assembly. 2. Assure that the flat of the sensor is aligned under the ridge of the reservoir and that the sensor connector is facing down in the fully seated position. This will allow for proper operation of the sensor float switch. 3. Connect the electrical body harness connectors to the fluid level sensor. Slide the red lock on the connector to the closed or locked position. 4. Assure that washer hose is properly routed to prevent pinching and possible inoperative washers. 5. Connect the left right front wheelhouse splash shield and move aside. 6. Install the right front wheel and tire assembly. 7. lower vehicle from hoist or jack stands. 8. Connect the battery negative cable. 9. Verify system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation Windshield Washer Switch: Description and Operation Instrument Panel Center Bezel On Automatic Temperature Control (ATC) vehicles only, the rear window wiper/washer switches are located on the center bezel with the hazard and heated seat switches. They are not serviceable separately from the hazard and heated seat switches. If defective, the entire switch assembly must be replaced. Rear Wiper/Washer Switch Location On Manual Temperature Control (MTC) vehicles only, the rear window wiper/washer switch is located on the HVAC control head attached to the center bezel. They are not serviceable separately from the control head. If found faulty, the entire MTC head must be replaced. When rear wiper operation is required, the BCM will provide ignition ON voltage to the rear wiper motor. When the wiper switch is turned OFF, the BCM provides circuit ground to operate the motor until the wipe cycle is complete and the wiper arm returns to the base of the rear window. The rear wiper/washer switch only offers an intermittent rear wiper mode. The wiper motor will cycle every 7 seconds. The intermittent delay time is also adjusted based upon vehicle speed. With the vehicle traveling greater than 50 mph, the cycle changes to every 5 seconds. When rear washer is requested by depressing and holding down the switch, the BCM then provides a ground for the rear washer motor. Until the switch is released, the motor will be in a continuous wipe mode, then return to an intermittent wipe mode. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 10509 Windshield Washer Switch: Testing and Inspection Wiper/Washer Switch Resistance 1. Remove the multi-function switch. 2. Using an ohmmeter check resistance readings between switch pins. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation Wiper Switch: Description and Operation Instrument Panel Center Bezel On Automatic Temperature Control (ATC) vehicles only, the rear window wiper/washer switches are located on the center bezel with the hazard and heated seat switches. They are not serviceable separately from the hazard and heated seat switches. If defective, the entire switch assembly must be replaced. Rear Wiper/Washer Switch Location On Manual Temperature Control (MTC) vehicles only, the rear window wiper/washer switch is located on the HVAC control head attached to the center bezel. They are not serviceable separately from the control head. If found faulty, the entire MTC head must be replaced. When rear wiper operation is required, the BCM will provide ignition ON voltage to the rear wiper motor. When the wiper switch is turned OFF, the BCM provides circuit ground to operate the motor until the wipe cycle is complete and the wiper arm returns to the base of the rear window. The rear wiper/washer switch only offers an intermittent rear wiper mode. The wiper motor will cycle every 7 seconds. The intermittent delay time is also adjusted based upon vehicle speed. With the vehicle traveling greater than 50 mph, the cycle changes to every 5 seconds. When rear washer is requested by depressing and holding down the switch, the BCM then provides a ground for the rear washer motor. Until the switch is released, the motor will be in a continuous wipe mode, then return to an intermittent wipe mode. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Failed Park Switch Wiper Switch: Testing and Inspection Failed Park Switch If the wiper park switch has failed, the windshield wipers will operate as follows: - SWITCH OFF - Wipers stop in current location regardless of the park signal. - INTERMITTENT MODE - Wipers operate continuously or at low speed for one or more extra wipes. - LOW SPEED - Wipers operate at low speed. - HIGH SPEED - Wipers operate at high speed. - WIPE AFTER WASH - Wipers operate at low speed in any mode setting. Wipers operate only while the wash button is depressed with switch in the OFF mode and wipers stop in mid-cycle when button is released. Wiper System Diagnosis Part 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Failed Park Switch > Page 10515 Wiper System Diagnosis Part 2 The windshield wiper park switch and circuit is monitored by the BCM. The park switch and circuit can be tested using the WIPER SYSTEM DIAGNOSIS table. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Failed Park Switch > Page 10516 Wiper Switch: Testing and Inspection Front Wiper/Washer Switch Wiper/Washer Switch Resistance 1. Remove the multi-function switch. 2. Using an ohmmeter check resistance readings between switch pins. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Connectors Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 10520 Washer Fluid Level Switch Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 10521 Washer Fluid Level Switch: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Hoist and support vehicle on hoist or jack stands. 3. If necessary, remove the right front wheel and tire assembly. 4. Disconnect the right front wheelhouse splash shield and move aside. 5. Drain washer fluid from the reservoir and into a suitable clean container. This can be done by disconnecting the windshield washer hose from the front (outboard) washer pump port allowing the washer fluid to drain into a container through a temporary jumper hose connected to the front washer pump. 6. Disconnect the electrical body harness connector to the the fluid level sensor. Slide the red lock on the connector to the release position, then, depress the black tab and pull the connector off the sensor. 7. Remove the sensor from reservoir by using a side foot to gently pry the sensor from the body of the reservoir. Do not damage the reservoir/sensor sealing surface or puncture reservoir during removal. CAUTION: To avoid damage to the sensor, assure the reservoir is in an upright position before removing the sensor from the reservoir. Do not rotate the sensor during removal. INSTALLATION 1. Use a new grommet when installing a new sensor assembly. 2. Assure that the flat of the sensor is aligned under the ridge of the reservoir and that the sensor connector is facing down in the fully seated position. This will allow for proper operation of the sensor float switch. 3. Connect the electrical body harness connectors to the fluid level sensor. Slide the red lock on the connector to the closed or locked position. 4. Assure that washer hose is properly routed to prevent pinching and possible inoperative washers. 5. Connect the left right front wheelhouse splash shield and move aside. 6. Install the right front wheel and tire assembly. 7. lower vehicle from hoist or jack stands. 8. Connect the battery negative cable. 9. Verify system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair Windshield Washer Hose: Service and Repair REMOVAL 1. Remove washer reservoir from vehicle. 2. Disconnect washer hose front the reservoir cavity. 3. Disconnect the washer hose from the reservoir pump. 4. Remove parts as necessary to replace washer hose (engine compartment, interior components, etc.). INSTALLATION 1. Install parts as necessary to after replacing washer hose (engine compartment, interior components, etc.). 2. Connect the washer hose to the reservoir pump. 3. Connect washer hose to the reservoir cavity. 4. Install the washer reservoir into vehicle. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams Windshield Washer Motor: Diagrams Lift Pump Motor (Diesel) Washer Pump Motor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Page 10528 Windshield Washer Motor: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Hoist and support vehicle on hoist or jack stands. 3. If necessary, remove the right front wheel and tire assembly. 4. Disconnect the right front wheelhouse splash shield and move aside. 5. Drain washer fluid from the reservoir and into a suitable clean container. This can be done by disconnecting the windshield washer hose from the front (outboard) washer pump port and allowing the washer fluid to drain into a container through a temporary jumper hose connected to the front washer pump port. 6. Disconnect the electrical body harness connectors to the washer pump motor. Slide the red lock on the connector to the release position, then, depress the black tab and pull the connector off the pump. 7. Remove pump from reservoir by pulling pump upper retention tab away from reservoir cavity and then lifting pump up from mounting grommet. Do not damage reservoir/pump sealing surface or puncture reservoir during removal. 8. Remove pump grommet and discard. INSTALLATION 1. Use new grommet when installing a new pump assembly. 2. Assure pump upper retention tab is pressed into reservoir slot and that pump is rotated flat against the reservoir and that pump connector is facing up in the fully seated position. Assure the pump is aligned to and fully seated in the reservoir cavity. 3. Connect the electrical body harness connectors to the washer pump motor. Slide the red lock on the connector to the closed or locked position. 4. Assure that washer hose is properly routed to prevent pinching and possible inoperative washers. 5. Connect the left right front wheelhouse splash shield and move aside. 6. Install the right front wheel and tire assembly. 7. lower vehicle from hoist or jack stands. 8. Connect the battery negative cable. 9. Verify system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair Windshield Washer Reservoir: Service and Repair REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the engine fresh air housing inside the engine compartment. 3. Disconnect the washer hose at the in-line connector forward of the cowl grille so that the in-line connector remains with the washer hose from the fresh air plenum. 4. Disconnect the washer hose from the hose clip located on the front fender side shield. 5. Remove the filler tube screw. 6. Hoist and support vehicle on hoist or jack stands. 7. Remove the right front wheel and tire assembly. 8. Disconnect the left right front wheelhouse splash shield and move aside. 9. Drain washer fluid from the reservoir and into a suitable clean container. This can be done by disconnecting the windshield washer hose from the front (outboard) washer pump port allowing the washer fluid to drain into a container through a temporary jumper hose connected to the washer pump port. 10. Disconnect the electrical body harness connectors to the washer pump motor and the fluid level sensor. Slide the red lock on the connector to the release position, then, depress the black tab and pull the connector off the pump or sensor. 11. Remove the two reservoir mounting screws. 12. Disconnect the reservoir from the body mount by raising the reservoir upward slightly and then down so that the reservoir filler neck and front washer hose pull through the opening in the front fender side shield. INSTALLATION 1. Push filler neck and front washer hose through the opening in the front fender side shield. Connect the reservoir to the body mount by lowering the reservoir down. 2. Install the two reservoir mounting screws. Torque screws to 8.5 - 11.3 N.m (75 - 100 in. lbs.). 3. Connect the electrical body harness connectors to the washer pump motor and the fluid level sensor. Slide the red lock on the connector to the closed or locked position. 4. Assure that washer is properly routed to prevent pinching and possible inoperative washers. 5. Install the left right front wheelhouse splash shield . 6. Install the right front wheel and tire assembly. 7. lower vehicle from hoist or jack stands. 8. Install the filler tube screw. Torque screw to 8.5 - 11.3 N.m (75 - 100 in. lbs.). 9. Connect the washer hose to the hose clip located on the front fender side shield. 10. Connect the washer hose at the in-line connector forward of the cowl grille. 11. Install the engine fresh air housing inside the engine compartment. 12. Connect the battery negative cable. 13. Verify system operation. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation Windshield Washer Switch: Description and Operation Instrument Panel Center Bezel On Automatic Temperature Control (ATC) vehicles only, the rear window wiper/washer switches are located on the center bezel with the hazard and heated seat switches. They are not serviceable separately from the hazard and heated seat switches. If defective, the entire switch assembly must be replaced. Rear Wiper/Washer Switch Location On Manual Temperature Control (MTC) vehicles only, the rear window wiper/washer switch is located on the HVAC control head attached to the center bezel. They are not serviceable separately from the control head. If found faulty, the entire MTC head must be replaced. When rear wiper operation is required, the BCM will provide ignition ON voltage to the rear wiper motor. When the wiper switch is turned OFF, the BCM provides circuit ground to operate the motor until the wipe cycle is complete and the wiper arm returns to the base of the rear window. The rear wiper/washer switch only offers an intermittent rear wiper mode. The wiper motor will cycle every 7 seconds. The intermittent delay time is also adjusted based upon vehicle speed. With the vehicle traveling greater than 50 mph, the cycle changes to every 5 seconds. When rear washer is requested by depressing and holding down the switch, the BCM then provides a ground for the rear washer motor. Until the switch is released, the motor will be in a continuous wipe mode, then return to an intermittent wipe mode. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 10535 Windshield Washer Switch: Testing and Inspection Wiper/Washer Switch Resistance 1. Remove the multi-function switch. 2. Using an ohmmeter check resistance readings between switch pins. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments Wiper Arm: Adjustments 1. Verify wiper blade element condition and wiper arm spring tension. Run wipers in low speed mode while applying water to the windshield. Observe the wiper blade that is chattering or skipping across the windshield. If the wiper element is not rolling over when the wiper direction reverses, align the wiper arm. The extension bar portion of the wiper arm must be twisted in the proper direction to allow the wiper element to roll over when the direction reverses. 2. Place two small adjustable wrenches placed 50 mm (2 in.) apart on the wiper arm extension rod. 3. Twist the extension rod slightly in the opposite direction that the element is laying on the windshield while holding the wrench closest to the pivot stationary. 4. Repeat Step 1, and align as necessary until wiper stops chattering and wipes the windshield clear. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Front Wiper Arm: Service and Repair Front REMOVAL CAUTION: The driver side wiper arm must be parked above the passenger side. Failure to do so will result in damage to the arms, blades or system. 1. Lift the arm cap upward. 2. Remove the nut holding wiper arm to the wiper pivot. Wiper Arm Removal 3. Using a suitable two jaw puller, separate the wiper arm from the wiper pivot. INSTALLATION 1. Verify that the wiper motor and linkage are in the park position. Wiper Arm Adjustment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Front > Page 10541 2. Place the wiper arm in position over the wiper pivot. 3. Install the nut to hold the wiper arm to the wiper pivot. Torque nut to 35 N.m (26 ft. lbs.). CAUTION: It is important to torque the wiper arm nut properly to insure that the wiper arm head does not strip and damage the arm, blade, and pivot of both wiper arms. 4. Push the arm cap cover down. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Front > Page 10542 Wiper Arm: Service and Repair Rear REMOVAL 1. Remove arm nut cap. 2. Remove wiper arm nut. 3. Pull wiper from pivot by rocking back and forth. INSTALLATION 1. Verify that wipers are in parked position. 2. Position arm on pivot. 3. Install wiper arm nut and torque to 20 N.m (175 in. lbs.). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak Windshield Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield NUMBER: 23-014-06 GROUP: Body DATE: March 8, 2006 SUBJECT: Windshield Wiper Blade/Element Maintenance MODELS: All All All Chrysler Group Vehicles DISCUSSION: Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the environmental conditions vehicles can be operated in, a film can build up on both the windshield and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in some instances, a chattering condition as the wipers blades travel across the windshield. Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that is required. If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper blades/elements is obvious, the following steps should be performed: 1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n 04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n 04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield. 2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth, paper towel or sponge. 3. Return the wiper blades to their normal operating position and function the washer system. If the wiper blades/elements are not streaking the windshield or chattering, replacing the blade assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times. If the wipe pattern is still objectionable, replace the wiper blades/elements. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Removal and Installation Wiper Blade: Service and Repair Removal and Installation REMOVAL 1. Lift the wiper arm away from the glass. Windshield Wiper Blade Rear Wiper 2. Disengage the release tab holding the wiper blade to the wiper arm and remove the wiper blade from the wiper arm. INSTALLATION 1. Position the blade onto the arm. 2. Engage the blade to the retainer by pulling up on the blade until the tabs snap into position. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Removal and Installation > Page 10558 Wiper Blade: Service and Repair Cleaning Wiper blades exposed to the weather for a long period of time tend to lose their wiping effectiveness. Periodic cleaning of the wiper blade is recommended to remove the accumulation of salt and road grime. The wiper blades, arms and windshield should be cleaned with a sponge or cloth and a mild detergent or nonabrasive cleaner. If the wiper blades continue to streak or smear, they should be replaced. The wiper blade should run smoothly across the windshield in both directions. The wiper blade should slightly roll over center when the blade reverses direction. A wiper blade insert that has lost flexibility or a wiper arm that has lost spring tension, will cause the blade to skip or chatter across the windshield. If the wiper blades are new and the wiper arm spring tension is OK and a chattering sound is emitted from the wiper(s), the wiper blade is not rolling over center. If this condition exists, refer to Wiper Arm/Adjustments. See: Wiper Arm/Adjustments Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade Heater > Component Information > Description and Operation Wiper Blade Heater: Description and Operation The defroster button located on the HVAC control controls the rear window defogger and the heated side view mirrors. When the defroster button is pushed, the HVAC control sends a bus message over the PCI bus to the Front Control Module (FCM) which controls the Rear Window Defogger relay. The defroster LED will illuminate when the defroster function is on. The defroster will function for 10 minutes or can be cycled off sooner by pressing the defroster button again. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Left Side Engine Compartment Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10565 Wiper Module Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10566 Wiper Control Module: Service and Repair REMOVAL 1. Release the hood latch and open hood. 2. Disconnect and isolate the battery negative cable. 3. Remove the wiper arms. 4. Remove the cowl cover. Wiper Module Wire Connector 5. Disconnect the positive lock on the wiper module wire connector. 6. Disconnect the wiper module wire connector from the engine compartment wire harness. 7. Disconnect the windshield washer hose from coupling outside the module. 8. Disconnect the drain tubes from nipples on bottom of the wiper module. 9. Remove nuts holding wiper module to lower windshield fence. Wiper Module 10. Remove bolts holding the wiper module to the dash panel. 11. Lift wiper module from weld-studs on lower windshield fence. CAUTION: Do not allow wiper module to rest on brake master cylinder reservoir, damage to brake system can result. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 10567 12. Remove wiper module. INSTALLATION NOTE:If replacing the wiper tub, the components must be transferred to the new tub. 1. Position the wiper module into the cowl. 2. Install the bolts that secure the wiper module to the dash (WIPER MODULE). Tighten bolts to 17 Nm (150 in. lbs.). 3. Install the nuts that retain the wiper module to the bulkhead fenceline. Tighten nuts to 7 Nm (62 in. lbs.). 4. Connect the drain tubes to the nipples on the wiper module. 5. Connect the windshield washer tube. 6. Connect the wire harness connector to the wiper module (WIPER MODULE). 7. Connect the positive lock on the wiper module wire connector (WIPER MODULE WIRE CONNECTOR). CAUTION: Do not allow wiper module to rest on brake master cylinder reservoir, damage to brake system can result. 8. Install the cowl cover. 9. Install the wiper arms and blades. Tighten nuts to 37 Nm (27 ft. lbs.). 10. Connect the battery negative cable. 11. Close the hood. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement Technical Service Bulletin # F10 Date: 060601 Recall - Wiper Motor Inspection/Replacement June 2006 Dealer Service Instructions for: Safety Recall F10 - Windshield Wiper Motor Models 2005-2006 (HB) Dodge Durango NOTE: This recall applies only to the above vehicles built between March 29, 2005 and June 12, 2005 (MDH 032905 through 061223) OR between September 27, 2005 and November 23, 2005 (MDH 092701 through 112323). 2005-2006 (RS) Chrysler Town & Country and Dodge Caravan/Grand Caravan NOTE: This recall applies only to the above vehicles built between March 28, 2005 and July 1, 2005 (MDH 032823 through 070123) OR between September 27, 2005and December 13, 2005(MDH 092701 through 121323). IMPORTANT: Vehicles that have already had the proper wiper module installed, according to warranty records, have been excluded from this recall. In addition, 2001 through 2006 model year RS vehicles (built outside of the above MDH ranges) that have had a suspect replacement windshield wiper motor (P/N 05114534AA) installed between March 21, 2005 and January 13, 2006, according to warranty records, have been added to this recall. Dealers are also requested to review their records and contact owners who have purchased a wiper motor or who have had a wiper motor installed outside of the warranty provision. There were no suspect HB replacement wiper motors shipped to Mopar. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The windshield wiper motor armature shaft on about 269,000 of the above vehicles may break and cause the windshield wipers to become inoperative. This can impair the driver's vision and cause a crash without warning. Repair The windshield wiper motor build date must be inspected and the wiper motor replaced if it is within certain build date ranges. Important: Notification to owners of involved vehicles will occur in two phases. Notification to owners of HB vehicles will begin in about one week. Notification to owners of RS vehicles will begin in about one month. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10576 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10577 Use of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification All dealers will receive a copy of this dealer recall notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Wiper Motor Build Date Inspection 1. If the vehicle is a: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10578 > HB, continue with Step 2. > RS, continue with Step 3. 2. Inspection of the HB wiper motor is as follows: a. Raise the hood. b. Using a mirror and a shop light, look at the bottom of the wiper motor and note the color of the label. > If the label is white, no further action is required. Return the vehicle to the customer. > If the label is yellow, continue with Section C - HB Yellow Label Inspection and Wiper Motor Replacement if Necessary. 3. Inspection of the RS wiper motor is as follows: a. Remove the two center screws holding the cowl grill (Figure 1). b. Raise the hood. c. Using a 1/2" piece of hard rubber (or equivalent), wedge open the joint between the cowl grill and the wiper module at the right washer nozzle (Figure 2). d. Using a shop light, look into the opening between the cowl grill and the wiper module for the label attached to the wiper motor. e. Note the color of the label: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10579 > If the wiper motor label is white, continue to Step 3f. > If the wiper motor label is yellow, continue to Step 4. f. Remove the wedge and close the hood. g. Install and tighten the two center cowl grill screws and return the vehicle to the customer. No further action is required. 4. Remove the wedge and lower the hood. 5. Remove each front windshield wiper arm as follows: a. Using a wax pencil, mark the park location of the wiper blades onto the windshield. b. Remove the wiper arm protective cap. c. Remove the nut holding the wiper arm to the wiper pivot shaft. d. Using a suitable two jaw puller (such as a battery terminal puller), separate the wiper arm from the wiper pivot shaft. e. Repeat Steps 5a through 5d for the other wiper arm. 6. Remove the two remaining screws securing the cowl cover to the wiper module. 7. Disengage the two quarter turn fasteners located near the wiper pivot shafts of the cowl grill from the body. Note the initial position of the arrow on the fastener is toward the windshield (Figure 3). 8. Open the hood. 9. Tape both rear corners of the hood and the fender edge by the cowl grill with masking tape or equivalent to prevent scratch damage to the cowl grill and paint during removal. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10580 10. Lift the cowl grill in the center and read the wiper motor date code (Figure 4). > If the date code (dd.mm.yy) is: 21.03.05 (21Mar05) through 15.05.05 (15May05) OR 21.09.05 (21Sep05) through 28.10.05 (28Oct05), continue with Section B - RS Wiper Motor Replacement > If the date code is not within the date ranges, continue with Step 11. 11. Install the center two screws of the cowl grill (Figure 1). 12. Remove the protective tape from the hood and fenders then carefully close the hood. 13. Install and tighten the four remaining screws securing the cowl cover to the wiper module. 14. Engage the two quarter turn fasteners located near the wiper pivot shafts of the cowl grill from the body (Figure 3). NOTE: The final position of the arrow on the fastener is toward the windshield. 15. Align the wiper arms to the respective marks on the windshield made in Step 5a and install the arms onto the wiper pivots. 16. Install the wiper arm nuts onto the wiper pivots and tighten to 25 ft-lb (35 N.m). CAUTION: It is important to tighten the wiper arm nut properly to avoid stripping the wiper arm head. The wiper arms must be aligned correctly to prevent damage to the wiper system. 17. Activate the windshield wipers to ensure proper function. 18. Install the windshield wiper arm caps and return the vehicle to the customer. B. RS Wiper Motor Replacement 1. Disconnect the battery. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10581 2. Disconnect the washer hose at the in line connector located near the air cleaner (Figure 5). 3. Lift the cowl grill and disconnect the washer hose grommet from the hole in the wiper module. Pull the washer hose and the grommet completely through the wiper module tub hole. 4. Remove the cowl grill. NOTE: Be careful not to scratch the cowl grill on fenders or the corner of the hood. 5. Remove the four fence nuts holding the wiper module inner brace to the lower windshield fence (Figure 6). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10582 6. Remove the four bolts under the wiper module inner braces holding the module tub to the dash panel (Figure 7). 7. Remove all four inner brace mounting nuts and pull the inner braces free of the mounting studs. The wiper module tub will drop down slightly (Figure 8). 8. Using a pair of 90° needle nose pliers, gently pry apart and disconnect the right and left wiper links from the right and left wiper crank balls (Figure 8). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10583 9. Remove the two left wiper assembly mounting nuts (Figure 9). 10. Remove the two right wiper assembly mounting nuts (Figure 10). 11. Lift the wiper motor assembly partially out of the module. 12. Unlock the red positive lock tab on the wiper module wire connector and disconnect the wiring harness connector from the wiper motor (Figure 11). Discard the old wiper motor assembly. 13. Install the new wiper motor assembly into the module tub. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10584 14. Connect the wire harness connector to the new wiper motor assembly. Lock the red positive lock tab of the connector. 15. Install the four wiper assembly mounting nuts and tighten to 80 in-lbs (9 N.m) (Figure 9 and 10). 16. Push the four inner support braces onto the studs. Install the four nuts and tighten to 80 in-lbs (9 N.m) (Figure 8). 17. Install the four bolts under the wiper module inner braces holding the module to the dash panel and tighten to 150 in-lbs (17 N.m) (Figure 7). 18. Install four the nuts holding the wiper module inner brace to the lower windshield fence and tighten to 65 in-lbs (7 N.m) (Figure 6) 19. Apply the grease supplied with this kit liberally on each of the wiper motor crank balls (Figure 12). 20. Attach the right and left wiper link ends to the right and left crank balls using slip-joint pliers. Apply just enough force to pop the link on. CAUTION: Excessive force will damage the plastic drive link bushings. 21. Position the cowl grill on the vehicle for installation. 22. Install the washer hose and the grommet into the wiper module tub. Be sure to properly seat the washer hose grommet into the bottom of the wiper module tub. 23. Connect the washer hose at the in line connector located by the air cleaner (Figure 5). 24. Install the cowl grill. NOTE: Be careful not to scratch the cowl grill, fender or the hood. 25. Install the two center screws to the cowl grill. 26. Connect the battery. 27. Remove the tape from the hood and fender then carefully close the hood. 28. Tighten the six screws securing the cowl cover to the wiper module. 29. Engage the two quarter turn fasteners located near the wiper pivot shafts of the cowl grill to the body (Figure 3). NOTE: The final position of the arrow on the fastener is toward the windshield. 30. Verify that the wiper motor and the linkage are in the park position by cycling the wiper system. Turn the ignition off. 31. Align the wiper arms to the respective marks made on the windshield in Section A Step 5a and install the wiper arms onto the wiper pivots. 32. Install the wiper arm nuts onto the wiper pivots and tighten to 25 ft-lb (35 N.m). CAUTION: It is important to tighten the wiper arm nut properly to avoid stripping the wiper arm head. The wiper arms must be aligned correctly to prevent damage to the wiper system. 33. Activate the windshield wipers to ensure proper function. 34. Install the wiper arm caps and return vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10585 C. HB Yellow Label Inspection and Wiper Motor Replacement If Necessary 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the three nuts that secure the front wiper arms to the pivot shafts (Figure 13). 3. Using a suitable two jaw puller, separate the wiper arms and the link from the wiper pivot shaft. 4. Remove the two cowl screws (Figure 13). 5. Remove the five push pin fasteners and discard them (Figure 13). 6. Lift the cowl grill off and place it away from the work area. 7. Unlock the red lock tab on the wiper module wire connector and disconnect the wiring harness connector from the wiper motor (Figure 14). 8. Insert the nose of a pair of 90o needle nose pliers underneath the right wiper link bushing and gently pry apart the wiper linkage from the wiper motor crank. (Figure 15) 9. Insert the nose of a pair of 90o needle nose pliers under the left wiper link bushing and gently pry apart the wiper linkage from the wiper motor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10586 crank. (Figure 15) 10. Remove the three bolts holding the wiper motor assembly to the wiper module and remove the motor. (Figure 15). 11. Read the wiper motor date code (Figure 16). > If the date code (dd.mm.yy) is: 21.03.05 (21Mar05) through 15.05.05 (15May05) OR 21.09.05 (21Sep05) through 28.10.05 (28Oct05), OR the date code is illegible, discard the old wiper motor. > If the date code is not within the two date ranges, reuse the old motor. motor. 12. Position the wiper motor so that the end of the wiper motor is facing the engine 13. Install the three wiper motor self tapping bolts removed in Step 10 and tighten to 62 in-lbs (7 N.m). (Figure 15) 14. If a new wiper motor is being installed, apply a light coating of grease (supplied in the kit) to the lower wiper motor crank ball. 15. Using a pair of slip joint pliers, snap the lower wiper linkage (left) onto the ball (Figure 15). Apply just enough force to pop the link on. CAUTION: Excessive clamping force will damage the plastic drive link bushing. 16 If a new wiper motor is being installed, liberally apply the remainder of the grease on the top half of the upper crank ball. 17. Using a pair of slip joint pliers, snap the upper wiper linkage (right) onto the ball (Figure 15). Apply just enough force to pop the link on. CAUTION: Excessive clamping force will damage the plastic drive link bushing. 18. Connect the wiring harness connector to the wiper motor connector. 19. Lock the red positive lock tab on the wiper module wire connector. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10587 20. Install the cowl grill and tighten the top rear two screws and the five front screws. 21. Connect the battery. 22. Verify that the wiper motor and the linkage are in the park position by cycling the wiper system. Turn off the ignition. 23. Position the wiper arms so that the blades align with the horizontal lines on the bottom of the windshield. Tighten the pivot nuts to 25 ft-lb (35 N.m). 24. Activate the windshield wipers to ensure proper function. 25. Return vehicle to the customer Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10588 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Recalls for Wiper Motor: > NHTSA06V067000 > Mar > 06 > Recall 06V067000: Wiper Motor Inspection/Replacement Wiper Motor: Recalls Recall 06V067000: Wiper Motor Inspection/Replacement MAKE/MODELS: MODEL/BUILD YEARS: Chrysler/Town and Country 2005-2006 Dodge/Caravan 2005-2006 Dodge/Durango 2005-2006 Dodge/Grand Caravan 2005-2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V067000 MFG'S REPORT DATE: March 07, 2006 COMPONENT: Visibility: Windshield Wiper/Washer: Motor POTENTIAL NUMBER OF UNITS AFFECTED: 268800 SUMMARY: On certain vans and sport utility vehicles, the front windshield wiper motor armature shaft may break. CONSEQUENCE: During certain operating conditions, loss of front windshield wiping capability could occur, and the driver's vision could be obscured which could result in a crash. REMEDY: Dealers will inspect and replace the windshield wiper motor free of charge. The manufacturer has not yet provided an owner notification schedule. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F10. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement Technical Service Bulletin # F10 Date: 060601 Recall - Wiper Motor Inspection/Replacement June 2006 Dealer Service Instructions for: Safety Recall F10 - Windshield Wiper Motor Models 2005-2006 (HB) Dodge Durango NOTE: This recall applies only to the above vehicles built between March 29, 2005 and June 12, 2005 (MDH 032905 through 061223) OR between September 27, 2005 and November 23, 2005 (MDH 092701 through 112323). 2005-2006 (RS) Chrysler Town & Country and Dodge Caravan/Grand Caravan NOTE: This recall applies only to the above vehicles built between March 28, 2005 and July 1, 2005 (MDH 032823 through 070123) OR between September 27, 2005and December 13, 2005(MDH 092701 through 121323). IMPORTANT: Vehicles that have already had the proper wiper module installed, according to warranty records, have been excluded from this recall. In addition, 2001 through 2006 model year RS vehicles (built outside of the above MDH ranges) that have had a suspect replacement windshield wiper motor (P/N 05114534AA) installed between March 21, 2005 and January 13, 2006, according to warranty records, have been added to this recall. Dealers are also requested to review their records and contact owners who have purchased a wiper motor or who have had a wiper motor installed outside of the warranty provision. There were no suspect HB replacement wiper motors shipped to Mopar. IMPORTANT: Some of the involved vehicles may be in dealer new vehicle inventory. Federal law requires you to complete this recall service on these vehicles before retail delivery. Dealers should also consider this requirement to apply to used vehicle inventory and should perform this recall on vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process. Subject The windshield wiper motor armature shaft on about 269,000 of the above vehicles may break and cause the windshield wipers to become inoperative. This can impair the driver's vision and cause a crash without warning. Repair The windshield wiper motor build date must be inspected and the wiper motor replaced if it is within certain build date ranges. Important: Notification to owners of involved vehicles will occur in two phases. Notification to owners of HB vehicles will begin in about one week. Notification to owners of RS vehicles will begin in about one month. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10598 Parts Information Completion Reporting and Reimbursement Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim Entry Screen located on the Service tab. Claims submitted will be used by DaimlerChrysler to record recall service completions and provide dealer payments. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10599 Use of the labor operation numbers and time allowances shown. NOTE: See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall claim processing instructions. Dealer Notification All dealers will receive a copy of this dealer recall notification letter by mail. Two additional copies will be sent through the DCMMS. To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab, then click on the description of this notification. Owner Notification and Service Scheduling All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement by first class mail. They are requested to schedule appointments for this service with their dealers. A generic copy of the owner letter is included. Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our records if applicable. Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall. This repair does not require hoists or other full service facility special equipment and is a DaimlerChrysler Mobile Service approved repair. Vehicle Lists, Global Recall System, VIP and Dealer Follow Up System (GRS) and Vehicle Information Plus (VIP) for dealer inquiry as needed. GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's name, address and phone number are listed if known. Completed vehicles are removed from GRS within several days of repair claim submission. To use this system, click on the "Service" tab and then click on "Global Recall System." Your dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at recall launch, those with a phone number, city, zip code, or VIN sequence. Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also use the VIN list to follow up with all owners to schedule appointments for this repair. Recall VIN lists may contain confidential, restricted owner name and address information that was obtained from the Department of Motor Vehicles of various states. Use of this information is permitted for this recall only and is strictly prohibited from all other use. Additional Information If you have any questions or need assistance in completing this action, please contact your Service and Parts District Manager. Customer Services Field Operations DaimlerChrysler Corporation A. Wiper Motor Build Date Inspection 1. If the vehicle is a: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10600 > HB, continue with Step 2. > RS, continue with Step 3. 2. Inspection of the HB wiper motor is as follows: a. Raise the hood. b. Using a mirror and a shop light, look at the bottom of the wiper motor and note the color of the label. > If the label is white, no further action is required. Return the vehicle to the customer. > If the label is yellow, continue with Section C - HB Yellow Label Inspection and Wiper Motor Replacement if Necessary. 3. Inspection of the RS wiper motor is as follows: a. Remove the two center screws holding the cowl grill (Figure 1). b. Raise the hood. c. Using a 1/2" piece of hard rubber (or equivalent), wedge open the joint between the cowl grill and the wiper module at the right washer nozzle (Figure 2). d. Using a shop light, look into the opening between the cowl grill and the wiper module for the label attached to the wiper motor. e. Note the color of the label: Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10601 > If the wiper motor label is white, continue to Step 3f. > If the wiper motor label is yellow, continue to Step 4. f. Remove the wedge and close the hood. g. Install and tighten the two center cowl grill screws and return the vehicle to the customer. No further action is required. 4. Remove the wedge and lower the hood. 5. Remove each front windshield wiper arm as follows: a. Using a wax pencil, mark the park location of the wiper blades onto the windshield. b. Remove the wiper arm protective cap. c. Remove the nut holding the wiper arm to the wiper pivot shaft. d. Using a suitable two jaw puller (such as a battery terminal puller), separate the wiper arm from the wiper pivot shaft. e. Repeat Steps 5a through 5d for the other wiper arm. 6. Remove the two remaining screws securing the cowl cover to the wiper module. 7. Disengage the two quarter turn fasteners located near the wiper pivot shafts of the cowl grill from the body. Note the initial position of the arrow on the fastener is toward the windshield (Figure 3). 8. Open the hood. 9. Tape both rear corners of the hood and the fender edge by the cowl grill with masking tape or equivalent to prevent scratch damage to the cowl grill and paint during removal. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10602 10. Lift the cowl grill in the center and read the wiper motor date code (Figure 4). > If the date code (dd.mm.yy) is: 21.03.05 (21Mar05) through 15.05.05 (15May05) OR 21.09.05 (21Sep05) through 28.10.05 (28Oct05), continue with Section B - RS Wiper Motor Replacement > If the date code is not within the date ranges, continue with Step 11. 11. Install the center two screws of the cowl grill (Figure 1). 12. Remove the protective tape from the hood and fenders then carefully close the hood. 13. Install and tighten the four remaining screws securing the cowl cover to the wiper module. 14. Engage the two quarter turn fasteners located near the wiper pivot shafts of the cowl grill from the body (Figure 3). NOTE: The final position of the arrow on the fastener is toward the windshield. 15. Align the wiper arms to the respective marks on the windshield made in Step 5a and install the arms onto the wiper pivots. 16. Install the wiper arm nuts onto the wiper pivots and tighten to 25 ft-lb (35 N.m). CAUTION: It is important to tighten the wiper arm nut properly to avoid stripping the wiper arm head. The wiper arms must be aligned correctly to prevent damage to the wiper system. 17. Activate the windshield wipers to ensure proper function. 18. Install the windshield wiper arm caps and return the vehicle to the customer. B. RS Wiper Motor Replacement 1. Disconnect the battery. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10603 2. Disconnect the washer hose at the in line connector located near the air cleaner (Figure 5). 3. Lift the cowl grill and disconnect the washer hose grommet from the hole in the wiper module. Pull the washer hose and the grommet completely through the wiper module tub hole. 4. Remove the cowl grill. NOTE: Be careful not to scratch the cowl grill on fenders or the corner of the hood. 5. Remove the four fence nuts holding the wiper module inner brace to the lower windshield fence (Figure 6). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10604 6. Remove the four bolts under the wiper module inner braces holding the module tub to the dash panel (Figure 7). 7. Remove all four inner brace mounting nuts and pull the inner braces free of the mounting studs. The wiper module tub will drop down slightly (Figure 8). 8. Using a pair of 90° needle nose pliers, gently pry apart and disconnect the right and left wiper links from the right and left wiper crank balls (Figure 8). Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10605 9. Remove the two left wiper assembly mounting nuts (Figure 9). 10. Remove the two right wiper assembly mounting nuts (Figure 10). 11. Lift the wiper motor assembly partially out of the module. 12. Unlock the red positive lock tab on the wiper module wire connector and disconnect the wiring harness connector from the wiper motor (Figure 11). Discard the old wiper motor assembly. 13. Install the new wiper motor assembly into the module tub. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10606 14. Connect the wire harness connector to the new wiper motor assembly. Lock the red positive lock tab of the connector. 15. Install the four wiper assembly mounting nuts and tighten to 80 in-lbs (9 N.m) (Figure 9 and 10). 16. Push the four inner support braces onto the studs. Install the four nuts and tighten to 80 in-lbs (9 N.m) (Figure 8). 17. Install the four bolts under the wiper module inner braces holding the module to the dash panel and tighten to 150 in-lbs (17 N.m) (Figure 7). 18. Install four the nuts holding the wiper module inner brace to the lower windshield fence and tighten to 65 in-lbs (7 N.m) (Figure 6) 19. Apply the grease supplied with this kit liberally on each of the wiper motor crank balls (Figure 12). 20. Attach the right and left wiper link ends to the right and left crank balls using slip-joint pliers. Apply just enough force to pop the link on. CAUTION: Excessive force will damage the plastic drive link bushings. 21. Position the cowl grill on the vehicle for installation. 22. Install the washer hose and the grommet into the wiper module tub. Be sure to properly seat the washer hose grommet into the bottom of the wiper module tub. 23. Connect the washer hose at the in line connector located by the air cleaner (Figure 5). 24. Install the cowl grill. NOTE: Be careful not to scratch the cowl grill, fender or the hood. 25. Install the two center screws to the cowl grill. 26. Connect the battery. 27. Remove the tape from the hood and fender then carefully close the hood. 28. Tighten the six screws securing the cowl cover to the wiper module. 29. Engage the two quarter turn fasteners located near the wiper pivot shafts of the cowl grill to the body (Figure 3). NOTE: The final position of the arrow on the fastener is toward the windshield. 30. Verify that the wiper motor and the linkage are in the park position by cycling the wiper system. Turn the ignition off. 31. Align the wiper arms to the respective marks made on the windshield in Section A Step 5a and install the wiper arms onto the wiper pivots. 32. Install the wiper arm nuts onto the wiper pivots and tighten to 25 ft-lb (35 N.m). CAUTION: It is important to tighten the wiper arm nut properly to avoid stripping the wiper arm head. The wiper arms must be aligned correctly to prevent damage to the wiper system. 33. Activate the windshield wipers to ensure proper function. 34. Install the wiper arm caps and return vehicle to the customer. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10607 C. HB Yellow Label Inspection and Wiper Motor Replacement If Necessary 1. Disconnect the negative battery cable. NOTE: To enhance customer satisfaction, remember to reset the clock when you have completed the service procedure. 2. Remove the three nuts that secure the front wiper arms to the pivot shafts (Figure 13). 3. Using a suitable two jaw puller, separate the wiper arms and the link from the wiper pivot shaft. 4. Remove the two cowl screws (Figure 13). 5. Remove the five push pin fasteners and discard them (Figure 13). 6. Lift the cowl grill off and place it away from the work area. 7. Unlock the red lock tab on the wiper module wire connector and disconnect the wiring harness connector from the wiper motor (Figure 14). 8. Insert the nose of a pair of 90o needle nose pliers underneath the right wiper link bushing and gently pry apart the wiper linkage from the wiper motor crank. (Figure 15) 9. Insert the nose of a pair of 90o needle nose pliers under the left wiper link bushing and gently pry apart the wiper linkage from the wiper motor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10608 crank. (Figure 15) 10. Remove the three bolts holding the wiper motor assembly to the wiper module and remove the motor. (Figure 15). 11. Read the wiper motor date code (Figure 16). > If the date code (dd.mm.yy) is: 21.03.05 (21Mar05) through 15.05.05 (15May05) OR 21.09.05 (21Sep05) through 28.10.05 (28Oct05), OR the date code is illegible, discard the old wiper motor. > If the date code is not within the two date ranges, reuse the old motor. motor. 12. Position the wiper motor so that the end of the wiper motor is facing the engine 13. Install the three wiper motor self tapping bolts removed in Step 10 and tighten to 62 in-lbs (7 N.m). (Figure 15) 14. If a new wiper motor is being installed, apply a light coating of grease (supplied in the kit) to the lower wiper motor crank ball. 15. Using a pair of slip joint pliers, snap the lower wiper linkage (left) onto the ball (Figure 15). Apply just enough force to pop the link on. CAUTION: Excessive clamping force will damage the plastic drive link bushing. 16 If a new wiper motor is being installed, liberally apply the remainder of the grease on the top half of the upper crank ball. 17. Using a pair of slip joint pliers, snap the upper wiper linkage (right) onto the ball (Figure 15). Apply just enough force to pop the link on. CAUTION: Excessive clamping force will damage the plastic drive link bushing. 18. Connect the wiring harness connector to the wiper motor connector. 19. Lock the red positive lock tab on the wiper module wire connector. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10609 20. Install the cowl grill and tighten the top rear two screws and the five front screws. 21. Connect the battery. 22. Verify that the wiper motor and the linkage are in the park position by cycling the wiper system. Turn off the ignition. 23. Position the wiper arms so that the blades align with the horizontal lines on the bottom of the windshield. Tighten the pivot nuts to 25 ft-lb (35 N.m). 24. Activate the windshield wipers to ensure proper function. 25. Return vehicle to the customer Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > F10 > Jun > 06 > Recall - Wiper Motor Inspection/Replacement > Page 10610 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiper Motor: > NHTSA06V067000 > Mar > 06 > Recall 06V067000: Wiper Motor Inspection/Replacement Wiper Motor: All Technical Service Bulletins Recall 06V067000: Wiper Motor Inspection/Replacement MAKE/MODELS: MODEL/BUILD YEARS: Chrysler/Town and Country 2005-2006 Dodge/Caravan 2005-2006 Dodge/Durango 2005-2006 Dodge/Grand Caravan 2005-2006 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID NUMBER: 06V067000 MFG'S REPORT DATE: March 07, 2006 COMPONENT: Visibility: Windshield Wiper/Washer: Motor POTENTIAL NUMBER OF UNITS AFFECTED: 268800 SUMMARY: On certain vans and sport utility vehicles, the front windshield wiper motor armature shaft may break. CONSEQUENCE: During certain operating conditions, loss of front windshield wiping capability could occur, and the driver's vision could be obscured which could result in a crash. REMEDY: Dealers will inspect and replace the windshield wiper motor free of charge. The manufacturer has not yet provided an owner notification schedule. Owners may contact DaimlerChrysler at 1-800-853-1403. NOTES: DaimlerChrysler recall No. F10. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Component Locations Wiper Motor: Component Locations Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Component Locations > Page 10617 Liftgate Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Connector Views Rear Wiper Motor Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front Wiper Motor: Service and Repair Front REMOVAL 1. Remove the front wiper motor from vehicle. 2. Remove four backwall bolts and four brace nuts. 3. Remove wiper linkage from wiper module. 4. Disconnect wire connectors from back of wiper motor. 5. Remove wiper linkage from motor crank. DO NOT remove crank from motor. 6. Remove bolts holding wiper motor and remove motor. INSTALLATION 1. Place wiper module on a suitable work surface. 2. Install wiper linkage into wiper unit. 3. Connect wire connectors to wiper motor. Wiper Module Wire Connector 4. Place the wiper module into engine compartment and connect wiper module wire connector to engine wire harness. 5. Install the four backwall bolts and four brace nuts to wiper module. 6. Operate wiper motor and verify that the wiper motor parks when wiper switch is turned OFF. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Front > Page 10622 Wiper Motor: Service and Repair Rear REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove rear wiper arm. 3. Open liftgate. 4. Remove liftgate trim panel. 5. Disconnect wire connector from rear wiper motor. 6. Remove screws holding rear wiper motor to lift-gate. 7. Remove wiper motor from liftgate. INSTALLATION 1. Position the wiper motor in the liftgate. 2. Install the retaining screws. 3. Connect the wire harness connector. 4. Install the liftgate trim panel. 5. Connect wire connector to rear wiper motor. 6. Install the screws holding rear wiper motor to liftgate. 7. Install the wiper motor to the liftgate. 8. Close the liftgate. 9. Install the wiper arm. 10. Connect the battery negative cable. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and Repair Wiper Motor Linkage: Service and Repair REMOVAL 1. Remove the front windshield wiper unit from vehicle. 2. Place the wiper unit on a suitable work surface. 3. Remove nuts holding the cowl cover brackets to the wiper unit. 4. Remove cowl cover brackets from the wiper unit. 5. Remove nuts holding linkage to the wiper unit. 6. Remove the wiper linkage from the wiper unit. 7. Disconnect the wire connectors from back of the wiper motor. INSTALLATION 1. Connect the wire harness connector. 2. Install the linkage on the wiper unit. 3. Install the nut holding the linkage to the wiper unit. 4. Install the cowl cover brackets to the wiper nut. 5. Install the front wiper unit. 6. Install the cowl cover. 7. Install the wiper arms and blades. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Integrated Power Module (Front View) Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation Wiper Switch: Description and Operation Instrument Panel Center Bezel On Automatic Temperature Control (ATC) vehicles only, the rear window wiper/washer switches are located on the center bezel with the hazard and heated seat switches. They are not serviceable separately from the hazard and heated seat switches. If defective, the entire switch assembly must be replaced. Rear Wiper/Washer Switch Location On Manual Temperature Control (MTC) vehicles only, the rear window wiper/washer switch is located on the HVAC control head attached to the center bezel. They are not serviceable separately from the control head. If found faulty, the entire MTC head must be replaced. When rear wiper operation is required, the BCM will provide ignition ON voltage to the rear wiper motor. When the wiper switch is turned OFF, the BCM provides circuit ground to operate the motor until the wipe cycle is complete and the wiper arm returns to the base of the rear window. The rear wiper/washer switch only offers an intermittent rear wiper mode. The wiper motor will cycle every 7 seconds. The intermittent delay time is also adjusted based upon vehicle speed. With the vehicle traveling greater than 50 mph, the cycle changes to every 5 seconds. When rear washer is requested by depressing and holding down the switch, the BCM then provides a ground for the rear washer motor. Until the switch is released, the motor will be in a continuous wipe mode, then return to an intermittent wipe mode. Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Failed Park Switch Wiper Switch: Testing and Inspection Failed Park Switch If the wiper park switch has failed, the windshield wipers will operate as follows: - SWITCH OFF - Wipers stop in current location regardless of the park signal. - INTERMITTENT MODE - Wipers operate continuously or at low speed for one or more extra wipes. - LOW SPEED - Wipers operate at low speed. - HIGH SPEED - Wipers operate at high speed. - WIPE AFTER WASH - Wipers operate at low speed in any mode setting. Wipers operate only while the wash button is depressed with switch in the OFF mode and wipers stop in mid-cycle when button is released. Wiper System Diagnosis Part 1 Dodge Grand Caravan Workshop Manual (V6-3.3L VIN R (2005)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Failed Park Switch > Page 10634 Wiper System Diagnosis Part 2 The windshield wiper park switch and circuit is monitored by the BCM. The park switch and circuit can be tested using the WIPER SYSTEM DIAGNOSIS table.